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MAINTENANCE INTERVALS - Safety

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1. g00920596 Illustration 122 The ejector guide rollers are located at the middle of the ejector There are two ejector guide rollers These rollers prevent the ejector from contacting the sides of the bowl These rollers prevent the ejector from cocking 1 Park the machine on level ground Engage the parking brake 2 Lower the bowl to the ground and close the apron 3 Check the adjustment for the ejector guide rollers The ejector guide rollers are correctly adjusted if the ejector does not contact the sides of the bowl The rollers should be in a position that prevents the ejector from rising too far above the floor of the bowl 4 Loosen roller shaft clamping bolt 1 5 Move eccentric roller shaft 2 to a position that allows the ejector to pass over the sides of the bowl 6 Tighten roller shaft clamping bolt 1 7 Repeat Step 4 through Step 6 in order to adjust the other ejector guide roller 8 Start the engine 9 Move the ejector forward and backward 10 Stop the engine SEBU7857 04 117 Maintenance Section Ejector Guide Rollers Inspect Pack Replace 11 Check for drag between the ejector guide rollers and the sides of the bowl Repeat the adjustment procedure if necessary 102501076 Ejector Guide Rollers Inspect Pack Replace SMCS Code 6230 040 6230 086 6230 510 S N DBY1 Up 7 A E
2. g00920902 Illustration 123 The ejector guide rollers are located at the middle of the ejector There are two ejector guide rollers These rollers prevent the ejector from contacting the sides of the bowl These rollers prevent the ejector from cocking 1 Park the machine on level ground Engage the parking brake 2 Lower the bowl to the ground and close the apron 3 Remove any debris from each ejector guide roller 4 Inspect the ejector guide rollers for damage Replace the ejector guide rollers if necessary 5 Pack the ejector guide rollers Consult your Caterpillar dealer for further information on this procedure i02501091 Ejector Support Rollers Check Adjust SMCS Code 6230 025 6230 535 S N DBY1 Up Illustration 124 g00920605 The ejector support rollers are located at the rear of the ejector There are two ejector support rollers These rollers support the rear portion of the ejector 1 Park the machine on level ground Engage the parking brake 2 Lower the bowl to the ground and close the apron 3 Check the adjustment for the ejector support rollers The ejector support rollers are correctly adjusted if the ejector support rollers run fully in the track 4 Loosen roller shaft clamping bolt 1 5 Move eccentric roller shaft 2 to a position that allows the roller to fully contact the track 6 Tighten roller shaft clampin
3. jas Illustration 118 g01128904 SEBU7857 04 115 Maintenance Section Ejector Carrier Rollers Check Adjust 1 Check the clearance between the draft arm wear plate 1 and the shoe 2 Refer to Specifications Draft Frame for the necessary clearance Add shims if necessary 2 Chock the wheels Illustration 119 g01128905 3 Use a suitable lifting device in order to lift the rear of the scraper Lift the rear of the scraper in order to place the bowl in the lowest possible position Support the rear of the scraper for safety 4 Remove the upper bolts for the wear plate 5 Remove cribbing and raise the bowl as far as possible 6 Remove lower bolts for the wear plate 7 Replace shims or replace the wear plate Repeat the procedure for the other side of the bowl 102444634 Ejector Carrier Rollers Check Adjust SMCS Code 6229 025 6229 535 S N DBY1 Up Two ejector carrier rollers are located at the base of the ejector These rollers prevent the ejector from contacting the floor of the bowl Check the adjustment for the ejector carrier rollers The ejector carrier rollers are correctly adjusted if the ejector does not contact the bottom of the bowl 1 Park the machine on level ground Engage the parking brake 2 Lower the bowl and the apron to the ground Illustration 120 3 Loosen roller shaf
4. 000 00O 668 Illustration 176 g01124705 The hydraulic oil sampling valve is located on top of the return tube near the hydraulic tank Type 2 ei EA A Illustration 177 g01781733 The hydraulic oil sampling valve is located on right side of the hitch near the grease block Refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations S O S Oil Analysis for information that pertains to obtaining a sample of hydraulic oil Refer to Special Publication PEHP6001 How To Take A Good Oil Sample for more information about obtaining a sample of hydraulic oil 102503169 Hydraulic Tank Breaker Relief Valve Clean SMCS Code 5118 070 S N DBC1 Up g01124743 Illustration 178 The hydraulic tank breaker relief valve is located on the top of the hydraulic tank near the hydraulic oil filler cap The hydraulic tank breaker relief valve controls the pressure in the tank and the vacuum in the tank 1 Clean debris from the breaker relief valve 2 Turn the breaker relief valve counterclockwise in order to remove the breaker relief valve Slowly remove the breaker relief valve in order to relieve pressure in the hydraulic tank 3 Remove the retaining ring from the top of the breaker relief valve 4 Remove the metal cover that is under the retaining ring A
5. 11 Tighten the filter according to the instructions that are printed on the filter Use the index marks as a guide for tightening the filter For non Caterpillar filters refer to the installation instructions that are provided by the supplier of the filter Note You may need to use a Caterpillar strap wrench or another suitable tool in order to turn the filter to the amount that is required for final installation Make sure that the installation tool does not damage the filter 12 Pump new oil into the engine Refer to the following topics e Operation and Maintenance Manual Lubricant Viscosities e Operation and Maintenance Manual Capacities Refill e Operation and Maintenance Manual Engine Oil Level Check 13 Remove the hose from the male coupler Install the dust cover 14 Start the engine and allow the oil to warm 15 Check the following items for leaks engine male fitting and engine oil filter 16 Shut off the engine 17 Run the engine for ten minutes 18 Check oil level gauge 3 Maintain the oil level between the marks on the LOW IDLE side of the oil level gauge If necessary add oil 102501551 Engine Oil Level Check SMCS Code 1000 535 FLV S N DBC1 Up Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact skin SEBU7857 04 129 Maintenance Section Engine Oil Sample Obtain NOTICE Do not
6. Check the seat belt mounting hardware 1 for wear or for damage Replace any mounting hardware that is worn or damaged Make sure that the mounting bolts are tight Check buckle 2 for wear or for damage If the buckle is worn or damaged replace the seat belt Inspect the seat belt 3 for webbing that is worn or frayed Replace the seat belt if the seat belt is worn or frayed Consult your Caterpillar dealer for the replacement of the seat belt and the mounting hardware Note Within three years of the date of installation or within five years of the date of manufacture replace the seat belt Replace the seat belt at the date which occurs first A date label for determining the age of the seat belt is attached to the seat belt the seat belt buckle and the seat belt retractor If your machine is equipped with a seat belt extension also perform this inspection procedure for the seat belt extension 102429594 Seat Belt Replace SMCS Code 7327 510 S N DBC1 Up Within three years of the date of installation or within five years of the date of manufacture replace the seat belt Replace the seat belt at the date which occurs first A date label for determining the age of the seat belt is attached to the seat belt the seat belt buckle and the seat belt retractor 1 2 UC cite 4 g01152685 Illustration 182 1 Date of installation retractor
7. Prime for further instructions Note The secondary fuel filter should also be changed at this time Refer to Operation and Maintenance Manual Fuel System Secondary Filter Replace for further instructions 15 Start the engine and check for leaks 136 Maintenance Section Fuel System Secondary Filter Replace SEBU7857 04 102502074 Fuel System Secondary Filter Replace SMCS Code 1261 510 SE S N DBC1 Up NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Illustration 159 g01115396 The secondary fuel filter is on the right side of the engine compartment above the primary fuel filter 1 Park the machine on a level surface Engage the parking brake 2 Lower the bowl to the ground Shut off the engine 3 Move fuel shutoff valve 3 to the CLOSED position 4 Clean secondary fuel filter 2 Clean filter mounting base 1 which is located above the filter 5 Turn the filter to the left in or
8. e The parking brake must be applied e The hydraulic oil must be warm e The transmission control must be in NEUTRAL e The bowl must be lowered Illustration 170 g01124542 Hydraulic oil filler cap 3 is located on top of the hydraulic tank 142 Maintenance Section SEBU7857 04 Hydraulic System Oil Filter Gear Pump and Case Drain Replace 1 Clean the hydraulic oil filler cap 2 The hydraulic oil filler cap is a locking cap If a padlock is on the cap remove the padlock Raise lever 4 in order to engage the lug 3 Turn the hydraulic oil filler cap counterclockwise in order to remove the cap Slowly remove the cap in order to relieve pressure in the hydraulic tank 4 Slowly remove hydraulic tank drain plug 2 5 Open hydraulic tank drain valve 1 Allow the oil to drain into a suitable container 6 Change the hydraulic system filters Refer to the following topics that apply to your machine e Operation and Maintenance Manual Hydraulic System Oil Filter Gear Pump and Case Drain Replace e Operation and Maintenance Manual Hydraulic System Oil Filter Pilot Replace e Operation and Maintenance Manual Hydraulic System Oil Filter Replace 7 Close the hydraulic tank drain valve 8 Clean the hydraulic tank drain plug Install the hydraulic tank drain plug 9 A screen is located under hydraulic oil filler cap 3 Remove the screen 10 Wash the screen in cl
9. Illustration 106 g01114916 1 Park the machine on level ground Engage the parking brake 2 Stop the engine 3 Check the coolant level in the sight gauge If the coolant level is at the bottom of the sight gauge more coolant is needed Note The filler tube has an angled cut inside of the coolant tank that can also be used to check the coolant level Add coolant when the coolant level reaches the bottom of the angled cut on the filler tube 4 If additional coolant is needed remove the pressure cap slowly in order to relieve the pressure 5 Add more coolant Note The radiator is full when the sight gauge is completely covered Also the radiator is full when the coolant level reaches the top of the angled cut on the filler tube 102500922 Cooling System Coolant Sample Level 1 Obtain SMCS Code 1350 008 S N DBC1 Up Note Obtaining a Coolant Sample Level 1 is optional if the cooling system is filled with Cat ELC Extended Life Coolant Cooling systems that are filled with Cat ELC should have a Coolant Sample Level 2 that is obtained at the recommended interval that is stated in the Maintenance Interval Schedule Note Obtain a Coolant Sample Level 1 if the cooling system is filled with any other coolant instead of Cat ELC This includes the following types of coolants e Commercial long life coolants that meet the Caterpillar Engine Coolant Specification 1 Caterpillar EC 1 e Cat Diesel Engi
10. Illustration 92 g01117288 1 Fan drive belt 2 Air conditioning compressor and alternator drive belt 1 Park the machine on level ground Move the transmission control to the NEUTRAL position and engage the parking brake Shut off the engine 2 Open the engine access cover that is on the right side of the tractor 3 Inspect the condition of the fan drive belt 1 Inspect the condition of the air conditioning compressor and alternator drive belt 2 Inspect the belts for the following conditions e excessive cracking e excessive wear e excessive stretching e excessive damage e missing pieces e frayed areas 4 Close the engine access cover Replace If the belts need replacement refer to the Service Manual or contact your local Caterpillar dealer 102443636 Brake Air System Pressure Test SMCS Code 4250 081 PX amp a cS j B p S Ss S N hy Illustration 93 g01220965 1 Start the engine and look at air pressure gauge 2 Allow the brake system air pressure to reach 850 50 kPa 125 10 psi 2 Apply the service brake by holding down service brake pedal 1 3 Stop the engine 4 The reading on the air pressure gauge should not drop by more than 35 kPa 5 psi after the engine is stopped for 10 minutes Repair the brakes if necessary SEBU7857 04 99 Maintenance Section Brake Air System Warning Horn Test 101401548 Brake Air System Warning Horn
11. 2 Date of installation buckle 3 Date of manufacture tag fully extended web 4 Date of manufacture underside buckle Consult your Caterpillar dealer for the replacement of the seat belt and the mounting hardware If your machine is equipped with a seat belt extension also perform this replacement procedure for the seat belt extension Secondary Steering Test If Equipped SMCS Code 4300 081 SST S N DBC1 Up Check the secondary steering system by using the following procedure 1 Install a pressure gauge and a hose in the secondary steering system Install the components between the ground driven secondary steering pump and the check valve 150 Maintenance Section Steering Pump Outlet Screen Clean SEBU7857 04 g00100829 Illustration 183 2 Route the pressure gauge to a location that allows the operator to see the gauge and safely drive the machine o Start the engine Operate the machine at approximately 16 km h 10 mph A Drive the machine in a straight line a Observe the gauge o If the gauge shows pressure the secondary steering pump is working N If the gauge does not show pressure repair the secondary steering pump or replace the secondary steering pump 102503829 Steering Pump Outlet Screen Clean SMCS Code 4306 070 Z3 S N DBC1 Up Illustration 184 g01116121 2 Illustration 185 g00922722 The ste
12. For non Caterpillar filters refer to the installation instructions that are provided by the supplier of the filter Note You may need to use a Caterpillar strap wrench or another suitable tool in order to turn the filter to the amount that is required for final installation Make sure that the installation tool does not damage the filter 9 Start the engine Check for leaks 10 Check the hydraulic oil level Add oil to the hydraulic tank if necessary Refer to Operation and Maintenance Manual Hydraulic System Oil Level Check for more information 102503089 Hydraulic System Oil Filter Pilot Replace SMCS Code 5068 510 PS S N DBC1 Up Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Illustration 172 g01124877 The pilot oil filter is located at the left rear of the tractor behind the
13. Cylinder Lubricate SEBU7857 04 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates 2 Clean the area around lower grease fitting 5 and upper grease fitting 6 3 Open upper grease fitting 6 by turning the fitting counterclockwise for one half turn 4 Attach a grease gun to lower grease fitting 5 Apply grease to the fitting until drive assembly 4 moves upward Grease will flow from vent 7 5 Insert shims 2 or remove shims 2 in order to achieve the proper chain adjustment Note Chain links may be removed from the elevator chain in order to obtain more adjustment for the elevator chain A half link may need to be removed A whole link may need to be removed Always remove the same number of links from each side of the elevator chain 6 Install bolt 3 Install locking nuts 1 Note Do not tighten the nuts at this time 7 Close upper grease fitting 6 by turning the fitting in a clockwise direction until the f
14. Dispose of all fluids according to local regulations and mandates Illustration 129 g00496695 Two grease fittings are located near the top of the assembly for the elevator One fitting is on the left side One fitting is on the right side The fittings lubricate the pin for the adjustment of the elevator chain SEBU7857 04 121 Maintenance Section Elevator Chain Idler Lubricate A relief valve is located on the inside of each of the pins The relief valve will prevent the O rings of the pin from being pushed out of place Do not try to apply grease to the relief valve 1 Clean the area around grease fitting 1 2 Apply grease to the fitting 3 Repeat Step 1 and Step 2 in order to lubricate the other pin 102501213 Elevator Chain Idler Lubricate SMCS Code 6248 086 S N DBY1 Up g00486735 g00495552 Illustration 131 Elevator chain idlers 1 are located on the elevator frame Two idlers are located on each side of the elevator frame 1 Park the machine on level ground Engage the parking brake 2 Lower the bowl to the ground 3 Clean the area around grease fittings 2 4 Apply grease through the fittings 5 Follow Step 3 and Step 4 for the other idlers 102501241 Elevator Chain Roller Check Lubricate SMCS Code 6260 086 6260 535 S N DBY1 Up Illustration 132 g01250801 Elevator chain rollers 2 are located at the lower end of the elevator frame One
15. Dryer Check cccceseccccceesseececeeseteeeeerenneneee 95 Belts Inspect Replace sccecceeeeeeeeeeeeeees 98 Brake Air System Pressure Test 0 eeeeeeee 98 Braking System Test 2 100 Differential and Final Drive Oil Level Check 114 Elevator Chain Roller Check Lubricate 121 Elevator Speed Reducer Check Lubricate 122 Engine Oil Sample Obtain a se 129 Hydraulic System Oil Sample Obtain 145 Transmission Oil Level Check 0 e 154 Transmission Oil Sample Obtain 155 Wheel Bearing Oil Level Check eee 156 Initial 500 Hours for New Systems Refilled Systems and Converted Systems Cooling System Coolant Sample Level 2 OD AIIM ees no aenta aaa a aaa Gamera 108 Every 500 Service Hours or 3 Months Accumulator Cushion Hitch Check assesses 95 Brake Camshaft Bearing Lubricate 0 99 Differential and Final Drive Oil Sample Obtain 114 94 Maintenance Section Maintenance Interval Schedule SEBU7857 04 Engine Oil High Speed and Oil Filter Change 127 Engine Oil and Filter Change n se 129 Fuel System Primary Filter Water Separator Element Replace aeee 134 Fuel System Secondary Filter Replace 136 Fuel Tank Cap and Strainer Clean 0 137 Hydraulic System Oil Filter Gear Pump and Case Drain Replace ccececcce
16. Illustration 187 g01222964 Measure the pressure of each tire with a tire gauge A regular tire gauge will work on tires that are inflated with nitrogen Note Scraper tires should be inflated with nitrogen gas in order to prevent the tires from exploding 1 Park the machine on level ground Apply the parking brake 2 Lower the bowl to the ground Shut off the engine 152 Maintenance Section Transmission Breather Clean SEBU7857 04 3 Clean the area around the valve stem for the tire 4 Remove valve stem cap 1 5 Measure the pressure of each tire with a tire gauge Add nitrogen gas if the pressure is low 6 Install the valve stem cap on the valve stem Refer to the following additional information about tire inflation e Operation and Maintenance Manual Tire Inflation with Nitrogen e Operation and Maintenance Manual Tire Shipping Pressure e Operation and Maintenance Manual Tire Inflation Pressure Adjustment Consult your Caterpillar dealer for further information on the correct operating pressures and the correct load ratings 102503846 Transmission Breather Clean SMCS Code 3030 070 BRE S N DBC1 Up Wie des BA La 1 Pa ONOFF Ea AA oF k rrr z g00923124 Illustration 188 The transmission breather is located on the top of the transmission at the right rear of the tractor Use the followin
17. Test SMCS Code 7402 081 7408 081 The warning horn for the air brake system should sound when the air pressure gauge shows a reading below 517 35 kPa 75 5 psi 1 The parking brake should be in the ENGAGED position 2 The transmission control should be in the NEUTRAL position 3 Start the engine 4 Watch the air pressure gauge The air pressure must be above 517 35 kPa 75 5 psi 5 Purge air from the air tanks by doing the following procedure e Engage and disengage the service brake until the air pressure drops below 517 35 kPa 75 5 psi The warning horn should sound and the action lamp should flash Make repairs if the warning horn is not sounding or the action lamp is not flashing 102556186 Brake Camshaft Bearing Lubricate SMCS Code 4251 086 BD l R A g00919030 Illustration 94 Tractor wheel A J lv A af Cae oO va g01152437 Illustration 95 Scraper wheel The grease fittings for the brake camshaft bearings can be reached from the back side of each wheel 1 Remove the covers that are on the fittings 2 Wipe the fittings before you apply lubricant through the fittings 3 Apply the appropriate lubricant through the fittings for the tractor wheels and for the scraper wheels in order to lubricate the brake camshaft bearin
18. and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates SEBU7857 04 113 Maintenance Section Differential and Final Drive Oil Change Illustration 113 g01250922 1 Differential drain plug 2 Transmission drain plug Differential drain plug 1 is located under the transmission of the tractor Transmission drain plug 2 is located behind the differential drain plug The differential drain plug is located closer to the front of the machine Operate the machine until the differential oil is warm 1 Park the machine on a level surface 2 Lower the bowl to the ground 3 Engage the parking brake Stop the engine 4 Clean the area around differential drain plug 1 5 Remove the differential drain plug Drain the oil into a suitable container 6 Clean the differential drain plug Install the differential drain plug g01221454 Illustration 114 3 Final drive filler plug 4 Final drive drain plug Note Final drive drain plug 4 is located on the hub of the wheel The final drive drain plug must be at the lowest point in order to drain the final drive Refer to Illustration 114 7 Clean the area around final drive drain plug 4 8 Remove the final drive drain plug Drain the oil into a suitable container 9 Clean the final drive drain plug Install the final drive drain plug 10 Repeat
19. element Clean the filter element with pressure air or wash the filter element in warm water Use a nonsudsing household detergent Rinse the filter element in clean water and air dry the filter element thoroughly 3 After you clean the filter element inspect the filter element Do not use a filter element with damaged pleats or a damaged seal If the filter element is damaged replace the filter element 4 Install the filter element Reinstall access cover 5 Replace latches 4 102500897 Circuit Breakers Reset SMCS Code 1420 529 S N DBC1 Up Circuit Breakers QO Illustration 101 g01229770 SEBU7857 04 103 Maintenance Section Clearance between Elevator Flight and Cutting Edge Check Adjust The circuit breakers for the tractor are located at the left side of the operator s seat Circuit Breaker Reset Push in the button in order to reset the circuit breaker If the electrical system is working properly the button will remain depressed If the button does not remain depressed check the appropriate electrical circuit Repair the electrical circuit if necessary C Blower Motor 1 20 AMP Keyswitch 2 10 AMP Headlamp 3 If Equipped 15 AMP Stop Tail Turn Lamp 4 If Equipped 10 AMP OO amp Circuit Breaker Panel Illustration 102 g01221006 The circuit breaker panel is located below the cab on the left side of the t
20. replacement of any major engine component If equipped replace the air filter indicator at least one time per year 1 Open the access door 2 Stop the engine Check the operation of service indicator 1 by pressing in reset button 2 on the service indicator This should require no more than three presses of the reset button 3 Next check the movement of the yellow piston in the service indicator Start the engine and accelerate the engine to high idle for a few seconds After the accelerator control pedal is released the yellow piston should remain at the highest position that was achieved during acceleration SEBU7857 04 127 Maintenance Section Engine Air Precleaner Clean 4 If the indicator will not reset easily replace the service indicator If the yellow piston of the indicator will not latch at the highest vacuum that is attained replace the service indicator 5 Close the access door 101550089 Engine Air Precleaner Clean SMCS Code 1055 070 S N DBC1 Up NOTICE Service the engine air precleaner only with the engine stopped Engine damage could result The engine air precleaner is positioned on top of the engine compartment L Illustration 143 g00805907 1 Loosen clamp 1 at the bottom of engine air precleaner 2 2 Remove engine air precleaner 2 and inspect the opening for dirt and debris Clean the tubes if necessary 3 Clean
21. roller is located on each side of the elevator frame 1 Park the machine on level ground Engage the parking brake 2 Lower the bowl to the ground 3 Position filler plug 1 so that the plug is near the top center of the roller Refer to Illustration 132 4 Clean the area around the filler plug Remove the filler plug 5 Maintain the oil level to the bottom of the filler hole If necessary add oil 6 Clean the filler plug Install the filler plug 7 Repeat Step 1 through Step 6 for the other elevator chain roller 122 Maintenance Section Elevator Drive Tube Roller Bearing Lubricate SEBU7857 04 102216611 Elevator Drive Tube Roller Bearing Lubricate SMCS Code 7551 086 ELV S N DBY1 Up g00929898 Illustration 133 The roller bearing for the elevator drive tube 1 is located on the right side of the elevator drive tube Refer to Disassembly and Assembly Elevator Drive Assemble for further information on repacking the bearings Consult your Caterpillar dealer for further information 100968135 Elevator Speed Reducer Check Lubricate SMCS Code 6236 086 ELV 6236 535 ELV S N DBY1 Up Tael g00493201 Illustration 134 The elevator speed reducer 1 is located at the top of the elevator The elevator speed reducer is on the left side of the elevator 1 Park the machine on level ground Lower the bowl Apply the parki
22. this procedure for the other wheel Illustration 115 g00920188 5 Oil filler tube for the differential 6 Sight gauge Note Oil filler tube 5 is located at the right rear of the tractor 11 Clean the area around the oil filler tube Remove the oil filler cap 12 Fill the differential with oil through the oil filler tube Fill the differential to the FULL mark in sight gauge 6 Refer to Operation and Maintenance Manual Capacities Refill and Operation and Maintenance Manual Lubricant Viscosities for further information 13 Clean the oil filler cap Install the oil filler cap Note The differential and the final drives share a common reservoir However the oil level of the final drives should be checked Final drive filler plug 3 must be horizontal with the center of the final drive in order to check the oil level of the final drive Final drive drain plug 4 will be at the bottom of the wheel Refer to Illustration 114 14 Clean the area around the final drive filler plug Remove the final drive filler plug 15 Oil should be dripping out of the filler plug hole when the final drive is full of oil If necessary add oil through the filler plug hole 114 Maintenance Section Differential and Final Drive Oil Level Check SEBU7857 04 16 Clean the final drive filler plug Install the final drive filler plug 17 Repeat this pr
23. transmission filter 1 Park the machine on a level surface and apply the parking brake 2 Stop the engine Lower the bowl to the ground 3 Clean the area around the pilot oil filter 4 Remove the filter with a strap type wrench Refer to Operation and Maintenance Manual Oil Filter Inspect Discard the used oil filter properly 5 Clean the filter mounting base Make sure that all of the old filter seal has been removed 6 Apply a thin film of clean hydraulic oil to the seal of the new filter 7 Install the new filter hand tight until the seal of the filter contacts the filter mounting base Note the position of the index marks on the filter in relation to a fixed point on the filter mounting base 144 Maintenance Section Hydraulic System Oil Filter Replace SEBU7857 04 Note There are rotation index marks on the filter that are spaced 90 degrees or 1 4 of a turn away from each other When you tighten the filter use the rotation index marks as a guide 8 Tighten the filter according to the instructions that are printed on the filter Use the index marks as a guide for tightening the filter For non Caterpillar filters refer to the installation instructions that are provided by the supplier of the filter Note You may need to use a Caterpillar strap wrench or another suitable tool in order to turn the filter to the amount that is required for final installation Make sure that the installation tool
24. under fill or overfill engine crankcase with oil Either condition can cause engine damage g01115060 Illustration 146 Oil level gauge 1 is located on the right side of the tractor 1 Park the machine on level ground Engage the parking brake 2 Lower the bowl to the ground 3 Open the engine access cover that is on the right side of the machine 4 Check the LOW IDLE side of the oil level gauge while the engine is running Maintain the oil level between the ADD mark and the FULL mark Check the ENGINE STOPPED side of the oil level gauge while the engine is stopped Maintain the oil level between the LOW mark and the FULL mark Note When you operate the machine on severe slopes the oil level in the engine crankcase must be at the FULL mark on the ENGINE STOPPED side of the oil level gauge g01116258 Illustration 147 5 Clean the area around oil filler cap 2 6 If necessary add oil by removing the oil filler cap 7 Clean the oil filler cap and install the oil filler cap 8 Close the engine access cover Engine Oil Sample Obtain SMCS Code 1000 008 7542 008 S N DBC1 Up g01115066 Illustration 148 The sampling valve for the engine oil is located on the filter base The engine oil filter is located on the right side of the engine in the engine compartment Refer to Specia
25. 0 Window Wiper Inspect Replace SMCS Code 7305 040 7305 510 S N DBC1 Up N g00907308 Illustration 199 One window wiper is located at the cab front window One window wiper is located at the cab rear window The window wipers have replaceable wiper blades Replace the wiper blades when the following conditions occur e The wiper blades streak the windows of the cab e The wiper blades are damaged e The wiper blades are worn Note Damaged wiper blades may cause permanent damage to the glass of the cab windows 102853227 Windows Clean SMCS Code 7310 070 S N DBC1 Up When cleaning the windows use the recommend ed procedure in this manual Serious injury or death could result from falling if the appropriate procedure and equipment is not used 158 Maintenance Section Windows Clean SEBU7857 04 DIDOONIDOON Illustration 200 g01421075 Clean the left side windows of the cab while you are standing on the ground or on a stable work platform Use the appropriate equipment in order to reach the left side windows If you are standing on the ground use a squeegee with an extension handle Clean the front right side and rear windows from the top of the engine enclosure Access this area by using the ladders and the walkways that are located on the right hand side of the m
26. 101 Maintenance Section Cab Air Filter Clean Replace 5 While the engine is at an idle and the service brake is applied move the transmission control to the SECOND SPEED position 6 Gradually increase the engine rpm The service brake should prevent machine movement when the engine is running at 1200 rpm or less If the machine moves with the engine rpm less than 1200 rpm consult your Caterpillar dealer for an inspection of the machine 7 Reduce the engine speed to low idle and move the transmission control to the NEUTRAL position Engage the parking brake Lower the bowl to the ground and stop the engine NOTICE If the machine moved while testing the brakes contact your Caterpillar Dealer Have the dealer inspect and if necessary repair the service brakes before returning the machine to operation Note If the friction material for the brakes needs to be replaced the new friction material may require conditioning for maximum performance Consult your Caterpillar dealer or see Special Instruction SEHS9187 for the procedure for conditioning Parking And Secondary Brake Holding Ability Test Make sure that no people or obstacles are in the area around the machine Test the brakes on a dry level surface Fasten the seat belt before you test the brakes This test determines whether the parking brake is functional This test is not intended to measure the maximum brake holding effort 1 Start the tractor en
27. 2 L 43 to 64 US gal 3 00 L 100 oz 4 40 L 148 oz Note For cooling systems with larger capacities use the formula in Table 12 in order to determine the correct amount of extender Table 12 Calculation of ELC Extender VM x 0 02 X2 1 V is the total volume of the cooling system 2 X is the amount of ELC Extender that is required For additional information about adding an extender see Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations Extended Life Coolant ELC or consult your Caterpillar dealer SEBU7857 04 107 Maintenance Section Cooling System Coolant Level Check 102500944 Cooling System Coolant Level Check SMCS Code 1350 535 FLV S N DBC1 Up Personal injury can result from hot coolant steam and alkali At operating temperature engine coolant is hot and under pressure The radiator and all lines to heaters or the engine contain hot coolant or steam Any contact can cause severe burns Remove filler cap slowly to relieve pressure only when engine is stopped and radiator cap is cool enough to touch with your bare hand Do not attempt to tighten hose connections when the coolant is hot the hose can come off causing burns Cooling System Conditioner contains alkali Avoid contact with skin and eyes The coolant level sight gauge is located on top of the radiator on the right side of the coolant tank
28. 501597 Fuel System Prime SMCS Code 1250 548 S N DBC1 Up NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates eae a Illustration 156 g01117169 The switch is located on the right side of the engine compartment underneath the hood The fuel priming pump is on the right side of the engine compartment underneath the hood Note The engine start switch must be in the OFF position in order to prime the fuel system Do not attempt to start the engine until the fuel system is purged of air The pump is used when any of the following procedures are performed e Changing the fuel filters e Priming the fuel system e Changing the fuel lines e Purging air from the fuel system 134 Maintenance Section SEBU7857 04 Fuel System Primary Filter Water Separator Element Replace Illustration 157 g01128777 1 Open the purge valve Hol
29. Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates NOTICE Do not fill fuel filters with fuel before installing them Contaminated fuel will cause accelerated wear to fuel system parts Fuel system should be primed prior to starting the engine SEBU7857 04 135 Maintenance Section Fuel System Primary Filter Water Separator Element Replace Illustration 158 g01115383 The primary fuel filter is on the right side of the engine compartment underneath the hood 1 Park the machine on a level surface Engage the parking brake 2 Lower the bowl to the ground Shut off the engine 3 Move fuel shutoff valve 4 to the CLOSED position 4 Clean primary fuel filter 2 Clean filter mounting base 1 which is located above the filter 5 Turn the filter to the left in order to loosen the filter Loosen the filter with a strap type wrench 6 Remove the filter Clean the bottom of the filter mounting base Make sure that all of the old filter seal is removed 7 Remove water separator bowl 3 from primary fuel filter 2 Clean the water separator bowl and clean the groove f
30. MAINTENANCE INTERVALS Operation and Maintenance Manual Excerpt 2010 Caterpillar CATERPILLAR All Rights Reserved A E y SEBU7857 04 ATERPILLAR ee Operation and Maintenance Manual 623G Wheel Tractor Scraper DBC1 Up Machine DBY1 Up Scraper SEBU7857 04 93 Maintenance Section Maintenance Interval Schedule 104024573 Maintenance Interval Schedule SMCS Code 1000 7000 7500 7519 Ensure that all safety information warnings and instructions are read and understood before any operation or any maintenance procedures are performed The user is responsible for the performance of maintenance including all adjustments the use of proper lubricants fluids filters and the replacement of components due to normal wear and aging Failure to adhere to proper maintenance intervals and procedures may result in diminished performance of the product and or accelerated wear of components Use mileage fuel consumption service hours or calendar time WHICH EVER OCCURS FIRST in order to determine the maintenance intervals Products that operate in severe operating conditions may require more frequent maintenance Note Before each consecutive interval is performed all maintenance from the previous interval must be performed When Required Battery Recycle oo eeeceeeeeeeeeeeeeeeeeeeeeeeeneaeees 97 Battery or Battery Cable Inspect Replace 97 Circuit Breakers Reset 0 eeecceeeeeee
31. There are rotation index marks on the filter that are spaced 90 degrees or 1 4 of a turn away from each other When you tighten the filter use the rotation index marks as a guide 10 Tighten the filter according to the instructions that are printed on the filter Use the index marks as a guide for tightening the filter For non Caterpillar filters refer to the installation instructions that are provided by the supplier of the filter Note You may need to use a Caterpillar strap wrench or another suitable tool in order to turn the filter to the amount that is required for final installation Make sure that the installation tool does not damage the filter SEBU7857 04 131 Maintenance Section Engine Valve Lash Check g01116290 Illustration 151 11 Clean the area around oil filler cap 5 12 Remove the oil filler cap Fill the crankcase with new oil Refer to the following topics e Operation and Maintenance Manual Lubricant Viscosities e Operation and Maintenance Manual Capacities Refill e Operation and Maintenance Manual Engine Oil Level Check 13 Clean the oil filler cap and install the oil filler cap 14 Start the engine and allow the oil to warm 15 Check the engine for leaks Check the filter for leaks 16 Run the engine for ten minutes 17 Check oil level gauge 4 Maintain the oil level between the marks on the LOW IDLE side of the oil level gauge If ne
32. achine Be sure to use the areas of the walkways that are covered with a slip resistant surface Use the provided handholds on the cab to maintain a secure position If necessary use a squeegee with an extension handle to fully reach across the front and rear windows Use commercially available window cleaning solutions to clean the windows
33. achine on level ground Apply the parking brake 2 Lower the bowl to the ground Shut off the engine 3 Clean the area around the housing for the suction screen 4 Remove drain plug 3 Allow the oil to drain into a suitable container 5 Remove bolts 1 for the cover of the suction screen 6 Remove cover 2 7 Remove the suction screen Clean the suction screen in nonflammable solvent 8 Inspect the suction screen for damage If the suction screen is damaged replace the suction screen 9 Install the suction screen 10 Inspect the seal for the cover Replace the seal if the seal is damaged 11 Clean the cover Install the cover 12 Clean the drain plug Install the drain plug 13 Start the engine 14 Check the area around the screen housing for leaks 15 Check the transmission oil level Add oil if necessary Refer to Operation and Maintenance Manual Transmission Oil Level Check for the proper procedure 16 Stop the engine 102449833 Tire Inflation Check SMCS Code 4203 535 Al Personal injury can result from improper tire infla tion A tire blowout or rim failure can result from im proper or misused equipment Use a self inflating chuck and stand behind the tread when inflating a tire Proper inflating equipment and training in using the equipment are necessary to avoid overinflat ing Before inflating tire put the tire in a restraining device
34. act with refrig erant Contact with refrigerant can cause frost bite Keep face and hands away to help prevent injury Protective goggles must always be worn when re frigerant lines are opened even if the gauges in dicate the system is empty of refrigerant Always use precaution when a fitting is removed Slowly loosen the fitting If the system is still un der pressure release it slowly in a well ventilated area Personal injury or death can result from inhaling refrigerant through a lit cigarette Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes released from a flame contacting air con ditioner refrigerant gas can cause bodily harm or death Do not smoke when servicing air conditioners or wherever refrigerant gas may be present Use a certified recovery and recycling cart to prop erly remove the refrigerant from the air condition ing system NOTICE If the refrigerant system has been open to the outside air without being plugged for more than 30 minutes the receiver dryer must be replaced Moisture will en ter an open refrigerant system and cause corrosion which will lead to component failure Illustration 180 g01159180 Refer to Service Manual SENR5664 Air Conditioning and Heating R 134a for All Caterpillar Machines for the proper procedure to change the r
35. air dryer Several weeks may be required in order to completely dry the system 101778591 Air Dryer Desiccant Replace SMCS Code 4285 510 DSS S N DBC1 Up Air lines to and from the air dryer must be at atmospheric pressure Release the air pressure from the air system completely before performing maintenance Illustration 89 g00909536 Replace the air dryer desiccant cartridge or rebuild the air dryer desiccant cartridge if water cannot be absorbed Consult your Caterpillar dealer for service or for replacement parts 101778832 Air Tank Moisture and Sediment Drain SMCS Code 4272 543 M amp S The air tanks should have some air pressure Check the air tanks at the end of the shift for moisture and for sediment Moisture and sediment can accumulate in the air tank This can lead to a low reserve of air The air dryer may need to be serviced Refer to Operation and Maintenance Manual Air Dryer Check for further information If oil is draining from the tanks consult your Caterpillar dealer Illustration 90 g00909442 Three valves 1 are on the left side of the tractor The valves are located in the recess for the step Open the valves Allow the moisture and the sediment to drain into a suitable container Close the valves SEBU7857 04 97 Maintenance Section Backup Alarm Test Illustration 91 g00909637 Th
36. alve Lash Check seese 131 Evaporator Coil and Heater Coil Clean 132 Hitch INSPCCt ccceececececeeeeeeeeeeeecceeeeeeeeeenees 139 Hydraulic System Oil Change eee 141 Wheel Bearing Oil Change n se 155 Every Year Cooling System Coolant Sample Level 2 Opa eres terre pee reer Perr ree reer eee errr 108 Engine Air Filter Service Indicator Inspect Replace cceeececceceeeeeeteeeeeetetteeeeees 126 Refrigerant Dryer Replace cceeeeeeeee 148 Every 3000 Service Hours or 2 Years Cooling System Pressure Cap Clean Replace 109 Cooling System Water Temperature Regulator Replace e ec eeeecccceceeceeeeeeeeeeeeeeecaeeeeeeeeeeeeeeeeseees 109 Crankshaft Vibration Damper Inspect 110 Every 3 Years After Date of Installation or Every 5 Years After Date of Manufacture Seat Belt Replace 20 00 0002 cceeeeeeeceeeeeeeeeeeees 149 Every 6000 Service Hours or 3 Years Cooling System Coolant Extender ELC Add 106 Every 12 000 Service Hours or 6 Years Cooling System Coolant ELC Change 105 SEBU7857 04 95 Maintenance Section Accumulator Cushion Hitch Check 102228281 Accumulator Cushion Hitch Check SMCS Code 5077 535 S N DBC1 Up z pm Illustration 86 g01124228 The cushion hitch accumulator is l
37. amples directly from the coolant sample port You should not obtain the samples from any other location Keep the lids on empty sampling bottles until you are ready to collect the sample e Place the sample in the mailing tube immediately after obtaining the sample in order to avoid contamination Never collect samples from expansion bottles e Never collect samples from the drain for a system Submit the sample for Level 1 analysis For additional information about coolant analysis refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer 102444355 Cooling System Coolant Sample Level 2 Obtain SMCS Code 1350 008 S N DBC1 Up NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Obtain the sample of the coolant as close as possible to the recommended sampling interval Supplies for collecting samples can be obtained from your Caterpillar dealer Refer to Opera
38. and engage the parking brake Stop the engine Allow the engine to cool 2 Loosen the cooling system pressure cap slowly in order to release the pressure Remove the cooling system pressure cap Illustration 105 g01115071 3 The coolant drain valve is located behind guard 2 Remove access cover 1 for the coolant drain valve 4 Open the coolant drain valve Drain the coolant into a suitable container 5 Flush the cooling system with clean water until the draining water is transparent 106 Maintenance Section Cooling System Coolant Extender ELC Add SEBU7857 04 6 Close the coolant drain valve Install the access cover 7 Add ELC Refer to the following topics e Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations Cooling System Specifications e Operation and Maintenance Manual Capacities Refill 8 Start the engine Operate the engine without the cooling system pressure cap until the water temperature regulator opens and the coolant level stabilizes 9 Check the coolant level The radiator is full when the sight glass is completely covered Also the radiator is full when the coolant level reaches the top of the angled cut on the filler tube Refer to Operation and Maintenance Manual Cooling System Coolant Level Check 10 Inspect the gasket of the cooling system pressure cap If the gasket is damaged replace the gasket 11 Install the
39. ation NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Illustration 171 g00669655 The filter for the gear pump and the case drain is on the right side of the transmission 1 Park the machine on a level surface Apply the parking brake SEBU7857 04 143 Maintenance Section Hydraulic System Oil Filter Pilot Replace 2 Lower the bowl to the ground Shut off the engine 3 Clean the area around the filter 4 Remove the filter with a strap type wrench Refer to Operation and Maintenance Manual Oil Filter Inspect Discard the used oil filter properly 5 Clean the filter mounting base Make sure that all of the old filter seal has been removed 6 Apply a thin coat of clean hydraulic oil to the seal of the new filter 7 Install the new filter hand tight until the seal of the filter contacts the filter mounting base Note the position of the index marks on the filter in relation to a fixed point on the filter mounting base Note There are rotation index marks on the filter that are spaced 90 degrees or 1 4 of a turn away from each other When you tighten the filter use the rotation index marks as a guide 8 Tighten the filter according to the instructions that are printed on the filter Use the index marks as a guide for tightening the filter
40. ative battery cable at the battery disconnect switch 7 Install the key for the battery disconnect switch Turn the key to the ON position i00993589 Battery Recycle SMCS Code 1401 561 Always recycle a battery Never discard a battery Always return used batteries to one of the following locations e A battery supplier e An authorized battery collection facility e Recycling facility 101851175 Battery or Battery Cable Inspect Replace SMCS Code 1401 040 1401 510 1402 040 1402 510 _ Turn the engine start switch to the OFF position Turn all switches to the OFF position 2 Turn the battery disconnect switch to the OFF position Remove the key p At the battery disconnect switch disconnect the negative battery cable that is connected to the frame Note Do not allow the disconnected battery cable to contact the disconnect switch 98 Maintenance Section Belts Inspect Replace SEBU7857 04 4 Disconnect the negative battery cable from the terminals of the battery 5 Perform the necessary repairs Replace the cable or the battery as needed 6 Connect the negative battery cable to the terminals of the battery 7 Connect the negative battery cable at the battery disconnect switch 8 Install the key for the battery disconnect switch Turn the key to the ON position 103639915 Belts Inspect Replace SMCS Code 1397 040 1397 510 S N DBC1 Up Inspect
41. cap remove the padlock Raise lever 2 in order to engage the lug 5 Turn the hydraulic oil filler cap counterclockwise in order to remove the cap Slowly remove the cap in order to relieve pressure in the hydraulic tank Replace the cap after you have relieved pressure in the hydraulic tank 6 Clean oil filter cover 3 Remove four bolts 4 that hold the oil filter cover in place 7 Remove the two filters Discard the filters properly 8 Remove the screen 9 Wash the screen in clean nonflammable solvent Inspect the screen for damage Replace the screen if the screen is damaged 1 So Install the screen Install two new filters 1 _ Inspect the O ring seal for the oil filter cover Replace the O ring seal if the O ring is damaged 1 N Install the oil filter cover 13 Refer to Operation and Maintenance Manual Hydraulic System Oil Level Check for further information SEBU7857 04 145 Maintenance Section Hydraulic System Oil Level Check 102503111 Hydraulic System Oil Level Check SMCS Code 5050 535 FLV S N DBC1 Up Note Before you check the hydraulic tank oil level the machine must meet the following conditions e The machine must be level e The parking brake must be applied e The hydraulic oil must be warm e The engine must be running at low idle e The transmission control must be in NEUTRAL e The cushion hitch must be in the OFF position e Th
42. cated at the left rear of the tractor Refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations S O S Oil Analysis for information that pertains to obtaining a sample of the transmission oil Refer to Special Publication PEHP6001 How To Take A Good Oil Sample for more information about obtaining a sample of the transmission oil i02503917 Wheel Bearing Oil Change SMCS Code 4234 044 OC S N DBY1 Up NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Illustration 195 g01128800 The wheel bearings are located on the rear wheels of the scraper 1 Clean the area around cover 1 2 Loosen bolts 2 Allow the oil to drain into a suitable container 3 Remove the bolts Clean the cover Clean the wheel 4 Inspect the gasket that is between the cover and the wheel for damage Replace the gasket if necessary 5 Install the cover Install the bolts 6 Remove oil filler plu
43. cessary add oil 18 Stop the engine 19 Close the engine access door 102243110 Engine Valve Lash Check SMCS Code 1105 535 S N DBC1 Up Ensure that the engine can not be started while this maintenance is being performed To help pre vent possible injury do not use the starting motor to turn the flywheel Hot engine components can cause burns Allow additional time for the engine to cool before mea suring adjusting valve lash clearance NOTICE Only qualified service personnel should perform this maintenance Refer to the Service Manual or your Caterpillar dealer for the complete valve lash adjust ment procedure Operation of Caterpillar engines with improper valve adjustments can reduce engine efficiency This re duced efficiency could result in excessive fuel usage and or shortened engine component life The initial valve lash adjustment is recommended at the first scheduled oil change The valve lash adjustment should then be made at every 2000 hour interval The adjustment is necessary due to the initial wear of the valve train components and to the seating of the valve train components This maintenance is recommended by Caterpillar as part of a lubrication and preventive maintenance schedule in order to help provide maximum engine life Ensure that the engine is stopped before measuring the valve lash To obtain an accurate measurement allow the valves to cool before this maintenance is perfo
44. coolant and shortens coolant life Use only Caterpillar products or commercial products that have passed the Caterpillar EC 1 specifications for pre mixed or concentrate coolants Use only Caterpillar Extender with Caterpillar ELC Failure to follow these recommendations could result in the damage to cool ing systems components If ELC cooling system contamination occurs see the topic Extended Life Coolant ELC in the Special Pub lication SEBU6250 Caterpillar Machine Fluids Rec ommendations NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates If the coolant in the machine is changed to Extended Life Coolant ELC from another type of coolant refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations Cat Extended Life Coolant ELC If the coolant is dirty or if you observe any foaming in the cooling system drain the coolant before the recommended interval 1 Park the machine on a level surface
45. cooling system pressure cap 12 Stop the engine 102336986 Cooling System Coolant Extender ELC Add SMCS Code 1352 544 NL S N DBC1 Up Personal injury can result from hot coolant steam and alkali At operating temperature engine coolant is hot and under pressure The radiator and all lines to heaters or the engine contain hot coolant or steam Any contact can cause severe burns Remove filler cap slowly to relieve pressure only when engine is stopped and radiator cap is cool enough to touch with your bare hand Do not attempt to tighten hose connections when the coolant is hot the hose can come off causing burns Cooling System Conditioner contains alkali Avoid contact with skin and eyes When Caterpillar Extended Life Coolant ELC is used an extender must be added to the cooling system See Operation and Maintenance Manual Maintenance Interval Schedule for the proper service interval The amount of extender is determined by the cooling system capacity Table 11 Amount of Caterpillar Extender ELC Recommended Amount of Caterpillar Extender Cooling System Capacity 22 to 30 L 6 to 8 US gal 0 57 L 20 oz 31 to 38 L 8 to 10 US gal 0 71 L 24 oz 39 to 49 L 10 to 13 US gal 0 95 L 32 oz 50 to 64 L 13 to 17 US gal 1 18 L 40 oz 65 to 83 L 17 to 22 US gal 1 60 L 54 oz 84 to 114 L 22 to 30 US gal 2 15 L 72 oz 115 to 163 L 30 to 43 US gal 164 to 24
46. d the drain hose to the container in order to catch the fuel Note Use a 4 L 1 US gal container in order to capture the fuel that will pass through the purge valve For capturing the fuel a drain hose is routed through the bottom of the mounting plate for the hydraulic tank 2 Push the switch upward to the ON position in order to pump the fuel Note If the pump will not pump fuel the pump may be faulty or an air leak may occur on the suction side of the fuel system 3 Continue to prime the fuel system until the flow of fuel is free of air bubbles Fuel should flow continuously from the hose 4 After air has been purged from the fuel system close the purge valve 5 Push the switch upward to the ON position for approximately 30 seconds in order to pressurize the fuel system 6 Start the engine Further priming may be necessary if any of the following conditions exist e The engine will not start e The engine starts but the engine continues to misfire e The engine starts but the engine continues to emit smoke 7 If the engine starts but the engine runs rough continue to run the engine at low idle until the engine runs smoothly 102502044 Fuel System Primary Filter Water Separator Element Replace SMCS Code 1260 510 1263 070 S N DBC1 Up NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product
47. d to the top of the bracket when the components of the elevator become worn Shims may need to be removed from the top of the bracket when you are working in loose material The space that is between the cutting edge and the elevator flight will become narrower 1 Park the machine on level ground Lower the bowl Apply the parking brake 2 You should raise the front of the elevator with a jack or a hoist Place blocks or stands under the front of the elevator once the elevator has been raised Lower the elevator until the elevator is resting on the blocks or stands Note The front of the elevator must not be resting on the top plate 3 Remove bolts 1 that hold plate 3 in place Remove plate 3 4 Remove bolts 2 Remove plate 4 5 Reposition shims 5 in order to achieve the proper distance 6 Replace plate 4 Replace bolts 2 7 Replace plate 3 Replace bolts 1 Note Bolts 1 have a special torque requirement Refer to Specifications SENR3130 Torque Specifications Ground Engaging Tool G E T Fasteners for the correct information 8 Follow Steps 3 through 5 in order to position the shims on the other side of the bowl 9 Lower the front of the elevator 102207380 Condenser Refrigerant Clean SMCS Code 1805 070 S N DBC1 Up NOTICE If excessively dirty clean condenser with a brush To prevent damage or bending of the fins do not use a stiff brush Repair t
48. der to loosen the filter Loosen the filter with a strap type wrench 6 Remove the filter Clean the bottom of the filter mounting base Make sure that all of the old filter seal is removed 7 Apply clean diesel fuel to the seal of the new filter 8 Install the new filter hand tight until the seal of the filter contacts the filter mounting base Note the position of the index marks on the filter in relation to a fixed point on the filter mounting base Note There are rotation index marks on the filter that are spaced 90 degrees or 1 4 of a turn away from each other When you tighten the filter use the rotation index marks as a guide 9 Tighten the filter according to the instructions that are printed on the filter Use the index marks as a guide for tightening the filter For non Caterpillar filters refer to the installation instructions that are provided by the supplier of the filter Note You may need to use a Caterpillar strap wrench or another suitable tool in order to turn the filter to the amount that is required for final installation Make sure that the installation tool does not damage the filter 10 Return the fuel shutoff valve to the OPEN position 11 Purge the air from the fuel system Refer to Operation and Maintenance Manual Fuel System Prime for further instructions Note The primary fuel filter should also be changed at this time Refer to Operation and Maintenance Manual Fuel System Pr
49. does not damage the filter 9 Start the engine Check for leaks at the pilot oil filter 10 Check the hydraulic oil level Add oil to the hydraulic tank if necessary Refer to Operation and Maintenance Manual Hydraulic System Oil Level Check for more information 102503105 Hydraulic System Oil Filter Replace SMCS Code 5068 510 S N DBC1 Up NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Illustration 173 g01124630 Oil filter cover 3 is located on top of the hydraulic tank Two oil filters and a screen are located under the oil filter cover The hydraulic tank is located in front of the right tractor wheel 1 Park the machine on level ground Apply the parking brake 2 Lower the bowl to the ground Shut off the engine 3 Clean hydraulic oil filler cap 1 The hydraulic oil filler cap is located on top of the hydraulic tank 4 The hydraulic oil filler cap is a locking cap If a padlock is on the
50. e 7452 040 S N DBC1 Up NOTICE Service the air cleaner only with the engine stopped Engine damage could result Illustration 141 g01116656 The engine air filter service indicator is located on the right side of the tractor in the engine compartment 1 Use a towel to remove the dust which has collected on indicator 1 2 Examine the indicator The machine may be operated when the indicator is yellow Note The machine should not be operated when the indicator is red If the indicator is red the air filter will need to be cleaned or the air filter will need to be replaced 3 Once the air filter has been checked the indicator should be reset Push in reset button 2 on the indicator The indicator will return to the yellow color Note Refer to Operation and Maintenance Manual Engine Air Filter Service Indicator Inspect Replace in order to check an engine air filter service indicator that is faulty Reference Operation and Maintenance Manual Engine Air Filter Primary Element Clean Replace Reference Operation and Maintenance Manual Engine Air Filter Secondary Element Replace 103195601 Engine Air Filter Service Indicator Inspect Replace If Equipped SMCS Code 7452 040 7452 510 S N DBC1 Up Illustration 142 g01156530 Note If equipped the air filter indicator should be replaced during engine overhauls If equipped the air filter indicator should be replaced during
51. e air tank for the scraper is on the right rear side of the scraper Open drain valve 2 Allow the moisture and the sediment to drain into a suitable container Close valve 2 103639910 Backup Alarm Test SMCS Code 7406 081 The backup alarm is on the rear of the machine 1 Turn the engine start switch to the ON position in order to perform the test 2 Apply the service brakes 3 Move the transmission control lever to the REVERSE position The backup alarm should start to sound immediately The backup alarm should sound immediately The alarm alerts the personnel behind the machine that the machine is backing up The backup alarm should continue to sound until the transmission control lever is moved to the NEUTRAL position or to the FORWARD position 101851167 Battery Clean Check SMCS Code 1401 070 1401 535 1402 070 1402 535 S N DBC1 Up 1 Turn the engine start switch to the OFF position Turn all switches to the OFF position 2 Turn the battery disconnect switch to the OFF position Remove the key 3 At the battery disconnect switch disconnect the negative battery cable that is connected to the frame Note Do not allow the disconnected battery cable to contact the disconnect switch 4 Check the battery terminals for corrosion If corrosion is present clean the battery terminals with a wire brush 5 Coat the battery terminals with petroleum jelly if necessary 6 Connect the neg
52. e ejector must be moved forward e Slight downward pressure must be applied on the bowl Illustration 174 g01124663 The hydraulic tank is located in front of the right tractor wheel Hydraulic oil filler cap 2 is located on top of the hydraulic tank 1 Clean sight gauge 1 in order to view the hydraulic tank oil level Illustration 175 g01124666 2 If necessary add oil to the hydraulic tank Note Clean hydraulic oil filler cap 2 before adding oil to the hydraulic tank 3 The hydraulic oil filler cap is a locking cap If a padlock is on the cap remove the padlock Raise lever 3 in order to engage the lug 4 Turn the hydraulic oil filler cap counterclockwise in order to remove the cap Slowly remove the cap in order to relieve pressure in the hydraulic tank 1 Add hydraulic oil until the oil level in the sight gauge is at the FULL level 2 Inspect the hydraulic oil filler cap for damage to the seal If the seal is damaged replace the seal 3 Install the hydraulic oil filler cap 103429784 Hydraulic System Oil Sample Obtain SMCS Code 5050 008 7542 008 S N DBC1 Up Note Your machine may be equipped with a Type 1 location of the sampling valve or a Type 2 location of the sampling valve 146 Maintenance Section Hydraulic Tank Breaker Relief Valve Clean SEBU7857 04 Type 1 ee ee08 cc
53. ean nonflammable solvent Inspect the screen for damage If the screen is damaged replace the screen 11 Install the screen 12 Fill the hydraulic tank to the proper level Refer to the following topics e Operation and Maintenance Manual Lubricant Viscosities e Operation and Maintenance Manual Capacities Refill e Operation and Maintenance Manual Hydraulic System Oil Level Check 13 Inspect the cap seal for damage If the seal is damaged replace the seal 14 Install the hydraulic oil filler cap 15 Start the machine Run the machine at a low idle 16 Check the hydraulic oil level The oil level should be above the ADD level in the sight gauge Add oil if necessary Note The oil must be free from bubbles If there are bubbles in the oil then air is entering the hydraulic system Inspect the suction hoses and the clamps If necessary tighten any loose clamps and any loose connections Replace any damaged hoses 17 Stop the engine 102503059 Hydraulic System Oil Filter Gear Pump and Case Drain Replace SMCS Code 5068 510 5091 510 S N DBY1 Up NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Public
54. ease i01276876 Hydraulic Oil Cooler Clean SMCS Code 1374 070 S N DBC1 Up The hydraulic oil cooler if equipped is located in front of the radiator for the tractor SEBU7857 04 141 Maintenance Section Hydraulic System Oil Change Clean the oil cooler and clean the radiator at the same time Clean the oil cooler in the same manner as you clean the radiator You can use compressed air high pressure water or steam to remove dust and other debris from the radiator core However the use of compressed air is preferred Note Care must be taken when you are using high pressure water High pressure water can cause damage to the radiator Use of a water spray nozzle on the pressure washer which will disperse the water pressure is preferred Note At the same interval clean the air conditioner condenser 103210861 Hydraulic System Oil Change SMCS Code 5056 044 S N DBC1 Up NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and ma
55. eceiver dryer assembly and for the procedure to reclaim the refrigerant gas 101696168 Rollover Protective Structure ROPS Inspect SMCS Code 7323 040 7325 040 S N DBC1 Up NOTICE Do not attempt to straighten the ROPS structure Do not repair the ROPS by welding reinforcement plates to the structure If there are any cracks in the welds in the castings or in any metal section of the ROPS consult your Cater pillar dealer for repairs 1 Inspect the ROPS for loose bolts Inspect the ROPS for damaged bolts Replace the damaged bolts and the missing bolts with original equipment parts only Torque the bolts to 1050 150 N m 775 110 Ib ft Note Apply oil to all ROPS bolt threads before you install the bolt Failure to apply oil can result in improper bolt torque 2 Operate the machine on a rough surface Replace the ROPS mounting supports if the ROPS makes a noise or if the ROPS rattles If there are any cracks in the welds in the castings or in any metal section of the ROPS consult your Caterpillar dealer for repairs SEBU7857 04 149 Maintenance Section Seat Belt Inspect 102429589 Seat Belt Inspect SMCS Code 7327 040 S N DBC1 Up Always check the condition of the seat belt and the condition of the seat belt mounting hardware before you operate the machine Replace any parts that are damaged or worn before you operate the machine Illustration 181 g00932801 Typical example
56. eeeeeeeeteeeeeetetieeeeees 142 Hydraulic System Oil Filter Pilot Replace 143 Hydraulic System Oil Filter Replace 144 Hydraulic Tank Breaker Relief Valve Clean 146 Transmission Oil Filter and Magnetic Screen Replace Clean cceceeceeeeeceeeeeceeeeeeeeeeeeeeneens 153 Every 1000 Service Hours or 6 Months Air Dryer Desiccant Replace cece 96 Battery Clean Check 0 ccccececeeeseeeeeeeeeeeeneeees 97 Brake Air System Warning Horn Test 26 99 Differential and Final Drive Breather Clean 112 Rollover Protective Structure ROPS Inspect 148 Suction Screen Transmission Scavenge CIC BIN Stet ices tte ete ne Aa Bee te 150 Transmission Breather Clean scce 152 Transmission Oil Change sses 152 Wheel Coolant Level Check ou 156 Every 2000 Service Hours Elevator Speed Reducer Oil Change 122 Every 2000 Service Hours or 1 Year Brake Shoes and Drums Inspect Replace 99 Condenser Refrigerant Clean s e 104 Differential Thrust Pin Clearance Check 112 Differential and Final Drive Oil Change 112 Ejector Carrier Rollers Inspect Pack Replace 116 Ejector Guide Rollers Inspect Pack Replace 117 Ejector Support Rollers Inspect Pack Replace 118 Electronic Unit Injector Inspect Adjust 118 Elevator Drive Tube Roller Bearing Lubricate 122 Engine V
57. enance Manual Blocking the Bowl Illustration 110 g01118723 4 If the cutting edges 1 are worn remove the bolts for the cutting edges 1 If the opposite sides of the cutting edges are not worn rotate the cutting edges and install the opposite sides of the cutting edges outward Clean the contact surfaces before installing 5 Install new cutting edge sections if the cutting edges are worn on both sides 6 If the end bits 2 are worn remove the bolts for the end bits 2 If the opposite sides of the end bits are not worn rotate the end bits and install the opposite sides of the end bits outward Clean the contact surfaces before installing 7 Install new end bits if the end bits are worn on both sides 8 Install the bolts and tighten the bolts to the specified torque See Service Manual SENR3130 Torque Specifications Ground Engaging Tool G E T Fasteners 9 Raise the bowl and remove the blocking Lower the bowl to the ground 10 After a few hours of operation check the bolts for proper torque Tighten the bolts if necessary 112 Maintenance Section Differential Thrust Pin Clearance Check SEBU7857 04 102444371 Differential Thrust Pin Clearance Check SMCS Code 3258 535 T9 S N DBC1 Up a N Y NI R d 5 A N A i Z g00919942 Illustration 111 The differential thrust pin is located at the front of the d
58. engine air precleaner 2 with pressure air or wash the engine air precleaner 2 in clean warm water 4 Install engine air precleaner 2 Tighten clamp 1 Engine Oil High Speed and Oil Filter Change SMCS Code 1318 510 HZ S N DBC1 Up Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Your machine may be equipped with a high speed arrangement for changing the engine oil The high speed arrangement allows the oil to be quickly withdrawn The high speed arrangement allows the oil to be quickly replaced The high speed arrangement has a hose which is attached to the oil pan at the drain hole The other end of the hose has a quick coupler Note Drain the crankcase while the oil is warm This allows waste particles that are suspended in the oil to drain As the oil cools the waste particles will settle to the bottom of
59. ering pump outlet screen is located inside the left frame rail of the tractor Note Clean the steering pump outlet screen when there is pump failure or when the pump is changed in the hydraulic system 1 Remove bolts 1 and elbow 2 2 Inspect seal 3 If the seal is damaged replace seal 3 3 Remove steering pump outlet screen 4 Clean the screen and the elbow in a nonflammable solvent 4 Install the steering pump outlet screen the seal the elbow and the bolts 102503841 Suction Screen Transmission Scavenge Clean SMCS Code 3030 070 Z3 S N DBC1 Up NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates SEBU7857 04 151 Maintenance Section Tire Inflation Check AS yi x m m 1 i 3 We T T g e k 1 la 5 SS 3 s J g01124806 Illustration 186 The suction screen for the transmission is located at the rear of the transmission 1 Park the m
60. errous metals can indicate wear on the aluminum parts of the engine such as main bearings rod bearings or turbocharger bearings Small amounts of debris may be found in the filter element This could be caused by friction and by normal wear Consult your Caterpillar dealer in order to arrange for further analysis if an excessive amount of debris is found Using an oil filter element that is not recommended by Caterpillar can result in severe engine damage to engine bearings to the crankshaft and to other parts This can result in larger particles in unfiltered oil The particles could enter the lubricating system and the particles could cause damage 101696128 Radiator Core Clean SMCS Code 1353 070 KO S N DBC1 Up You can use compressed air high pressure water or steam to remove dust and other debris from the radiator core However the use of compressed air is preferred Note Care must be taken when you are using high pressure water High pressure water can cause damage to the radiator If you use high pressure water use a water spray nozzle on the pressure washer which will disperse the water pressure See Special Publication SEBD0518 Know Your Cooling System for the complete procedure for cleaning the radiator core 148 Maintenance Section Refrigerant Dryer Replace SEBU7857 04 102318448 Refrigerant Dryer Replace SMCS Code 7322 710 S N DBC1 Up Personal injury can result from cont
61. fer to Operation and Maintenance Manual Transmission Oil Level Check for the proper procedure 13 Start the engine Run the engine at low idle 14 Check the transmission oil filter for leaks Check the magnetic screen for leaks 15 Check the oil level of the transmission Add oil if necessary 16 Stop the engine 102503889 Transmission Oil Level Check SMCS Code 3030 535 FLV S N DBC1 Up Illustration 193 g01253192 1 Transmission oil filler tube 2 Transmission sight gauge Transmission sight gauge 2 is located on the back right side of the transmission SEBU7857 04 155 Maintenance Section Transmission Oil Sample Obtain 1 Park the machine on level ground Place the transmission in NEUTRAL and apply the parking brake 2 Lower the bowl to the ground Run the engine at low idle 3 Clean the area around transmission sight gauge 2 and transmission oil filler tube 1 4 Maintain the oil level between the FULL mark and the ADD mark on the transmission sight gauge 5 Remove the oil filler cap and add oil if necessary 6 Clean the oil filler cap and install the oil filler cap 7 Stop the engine 102503913 Transmission Oil Sample Obtain SMCS Code 3030 008 7542 008 S N DBC1 Up h 7 IAAI O Illustration 194 g01124873 The sampling valve for the transmission is lo
62. filter is under the metal cover 5 Wash the breaker relief valve and wash the filter in a clean nonflammable solvent 6 Dry the breaker relief valve Dry the filter Use compressed air in order to speed the drying 7 Inspect the filter for damage If the filter is damaged replace the filter 8 Inspect the O ring that is between the filter and the housing of the hydraulic tank breaker relief valve If the O ring is damaged replace the O ring 9 Inspect the breaker relief valve for damage If the breaker relief valve is damaged replace the breaker relief valve SEBU7857 04 147 Maintenance Section Oil Filter Inspect 10 Apply a thin film of clean hydraulic oil to the O ring Assemble the filter on the breaker relief valve 11 Install the breaker relief valve on the hydraulic tank 102106227 Oil Filter Inspect SMCS Code 1308 507 3004 507 3067 507 5068 507 S N DBC1 Up Inspect a Used Filter for Debris Illustration 179 g00100013 The element is shown with debris Use a filter cutter to cut the filter element open Spread apart the pleats and inspect the element for metal and for other debris An excessive amount of debris in the filter element can indicate a possible failure If metals are found in the filter element a magnet can be used to differentiate between ferrous metals and nonferrous metals Ferrous metals can indicate wear on steel parts and on cast iron parts Nonf
63. for cleaning primary air filter elements which require daily cleaning because of a dry dusty environment Cleaning with pressurized air is recommended prior to vacuum cleaning Vacuum cleaning will not remove deposits of carbon and oil SEBU7857 04 125 Maintenance Section Engine Air Filter Secondary Element Replace Inspecting the Primary Air Filter Elements Illustration 138 g00281693 Inspect the clean dry primary air filter element Use a 60 watt blue light in a dark room or in a similar facility Place the blue light in the primary air filter element Rotate the primary air filter element Inspect the primary air filter element for tears and or holes Inspect the primary air filter element for light that may show through the filter material If it is necessary in order to confirm the result compare the primary air filter element to a new primary air filter element that has the same part number Do not use a primary air filter element that has any tears and or holes in the filter material Do not use a primary air filter element with damaged pleats gaskets or seals Discard damaged primary air filter elements Storing Primary Air Filter Elements If a primary air filter element that passes inspection will not be used the primary air filter element can be stored for future use Illustration 139 g00281694 Do not use paint a waterproof cover or plastic as a protective covering for storage An air flo
64. g 3 Fill the wheel bearing with oil Maintain the oil level at the bottom of the opening for the oil filler plug Refer to the following topics 156 Maintenance Section Wheel Bearing Oil Level Check SEBU7857 04 e Operation and Maintenance Manual Lubricant Viscosities e Operation and Maintenance Manual Capacities Refill 7 Clean the oil filler plug and install the oil filler plug Repeat the procedure for the other wheel 102503939 Wheel Bearing Oil Level Check SMCS Code 4234 535 FLV S N DBY1 Up Illustration 196 901128618 The wheel bearings are located on the rear wheels of the scraper 1 Clean the surface around the oil filler plug Remove the oil filler plug 2 Ensure that the oil level is maintained at the bottom of the opening for the oil filler plug 3 Clean the oil filler plug and install the oil filler plug Repeat the procedure for the wheel 102446418 Wheel Coolant Level Check SMCS Code 4207 535 FLV With a lack of wheel coolant personal injury or death can result The brakes can generate enough heat to burn the tire bead A burning bead produces gases inside the tire that can explode endangering personnel within 500 meters 1500 feet Illustration 197 g01222390 Check fill plug 1 for the wheel coolant is located on the outer edge of the wheel Note The check fill plug is easily confused with final drive drain plug 2 Refer to Operat
65. g bolt 1 7 Repeat Step 4 through Step 6 in order to adjust the other ejector support roller 8 Start the engine 9 Move the ejector forward and backward 10 Stop the engine 11 Check for drag between the ejector and the sides of the frame Repeat the adjustment procedure if necessary 118 Maintenance Section Ejector Support Rollers Inspect Pack Replace SEBU7857 04 102501093 Ejector Support Rollers Inspect Pack Replace SMCS Code 6230 040 6230 086 6230 510 S N DBY1 Up Vp N Hoo Illustration 125 g00921939 Two ejector support rollers are located at the rear of the ejector 1 Park the machine on level ground Engage the parking brake 2 Lower the bowl to the ground and close the apron 3 Remove any debris from each ejector support roller 4 Inspect the ejector support rollers for damage Replace the ejector support rollers if necessary 5 Pack the ejector support rollers Consult your Caterpillar dealer for further information on this procedure 101798044 Electronic Unit Injector Inspect Adjust SMCS Code 1251 025 1251 040 1290 025 1290 040 S N DBC1 Up Be sure the engine cannot be started while this maintenance is being performed To prevent pos sible injury do not use the starting motor to turn the flywheel Hot engine components can cause burns Allow additional time for the engine to cool before mea suring adjusting the unit
66. g procedure to clean the breather 1 Clean the area around the breather 2 Remove the breather 3 Wash the breather in clean nonflammable solvent 4 Allow the breather to dry 5 Install the breather i02503848 Transmission Oil Change SMCS Code 3030 044 S N DBC1 Up Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates ee Y NX ie Illustration 189 g01250922 1 Differential drain plug 2 Transmission drain plug Transmission drain plug 2 is located under the tractor Differential drain plug 1 is closer to the front of the machine Note Operate the machine until the transmission oil is warm 1 Park the machine on a level surface Apply the parking brake SEBU7857 04 153 Maintenance Section Transmission Oil Filter and Magnetic Screen Replace Clean 2 Lower the bowl to the ground Stop
67. gasket is provided with each new ether cylinder 3 Install the new ether cylinder Tighten the ether cylinder hand tight Tighten the cylinder retaining clamp with your fingers 102229995 Evaporator Coil and Heater Coil Clean SMCS Code 7309 070 7343 070 S N DBC1 Up g01124895 Illustration 154 Heater coil 3 and evaporator coil 4 are located in front of the operator compartment on the left side of the machine The coils are located on the top of the heating and air conditioning unit The coils are protected by cover 1 and cover 2 1 Remove cover 1 Next remove cover 2 2 Clean heater coil 3 and evaporator coil 4 3 Replace cover 2 Next replace cover 1 SEBU7857 04 133 Maintenance Section Floor Rollers Lubricate Note If you are operating the machine under harsh conditions or with the cab door open it may be necessary to clean the coils more often 102501593 Floor Rollers Lubricate SMCS Code 6228 086 S N DBY1 Up g00754904 Illustration 155 The elevator floor rollers are located on the door assembly Two rollers are located on each side of the assembly 1 Park the machine on level ground Engage the parking brake 2 Lower the bowl to the ground 3 Clean the area around the grease fittings for the rollers 4 Apply grease to the fittings on both sides of the machine 102
68. gine and the scraper engine Scroll to Numeric Readout Mode on display area 1 Look at the air pressure on display area 1 Allow the brake system air pressure to reach the cut out pressure for the throttle 2 Disengage the scraper transmission by moving the scraper transmission neutral run switch to the DISENGAGE position 3 Raise the bowl 4 Apply the parking brake 5 While the engine is at an idle and the parking brake is applied move the transmission control to the SECOND SPEED position If the machine begins to move reduce the engine speed immediately and apply the service brake pedal 6 Gradually increase the engine rpm The parking brake should prevent machine movement when the engine is running at 1000 rpm or less If the machine moves with the engine rpm less than 1000 rpm consult your Caterpillar dealer for an inspection of the machine 7 Reduce the engine speed and move the transmission control to the NEUTRAL position Lower the bowl to the ground and stop the engine NOTICE If the machine moved while testing the brakes contact your Caterpillar Dealer Have the dealer inspect and if necessary repair the service brakes before returning the machine to operation Note If the friction material for the brakes needs to be replaced the new friction material may require conditioning for maximum performance Consult your Caterpillar dealer or see Special Instruction SEHS9187 for the procedure for c
69. gs 4 Replace the covers for the fittings 101792845 Brake Shoes and Drums Inspect Replace SMCS Code 4252 040 4252 510 4253 040 4253 510 Illustration 96 g00920131 Front Wheel Note Check the brakes on all four wheels Rear wheels are similar to the front wheels 1 Remove the wheel brake dust covers 100 Maintenance Section Brakes Indicators and Gauges Test SEBU7857 04 2 Check the brake shoes for wear or for damage Measure the thickness of the brake linings If the thickness of the brake linings is less than 7 2 mm 0 28 inch replace the brake linings 3 Check the brake drum for wear or for damage Repair the brake drum or replace the brake drum if necessary 4 Install the wheel brake dust cover 102444593 Brakes Indicators and Gauges Test SMCS Code 4251 081 4267 081 7000 7450 081 7490 081 Before you operate the machine perform the following checks and make any necessary repairs 1 Look for broken lenses on the gauges broken indicator lights broken switches and other broken components in the cab 2 Start the engine 3 Look for inoperative gauges 4 Turn on all machine lights Check for proper operation 5 Sound the forward horn 6 Move the machine forward and test the service brakes If the service brakes malfunction consult your Caterpillar dealer for proper repair 7 Engage the
70. he fins if found defective Illustration 104 g01114468 The refrigerant condenser is located behind the front radiator grill 1 Remove the radiator grill 2 Inspect the condenser for debris If necessary clean the condenser 3 Use clean water in order to wash off all dust and dirt from the condenser 4 Replace the radiator grill SEBU7857 04 105 Maintenance Section Cooling System Coolant ELC Change 102500932 Cooling System Coolant ELC Change SMCS Code 1350 044 NL S N DBC1 Up Personal injury can result from hot coolant steam and alkali At operating temperature engine coolant is hot and under pressure The radiator and all lines to heaters or the engine contain hot coolant or steam Any contact can cause severe burns Remove filler cap slowly to relieve pressure only when engine is stopped and radiator cap is cool enough to touch with your bare hand Do not attempt to tighten hose connections when the coolant is hot the hose can come off causing burns Cooling System Conditioner contains alkali Avoid contact with skin and eyes NOTICE Do not change the coolant until you read and under stand the cooling system information in Special Pub lication SEBU6250 Caterpillar Machine Fluids Rec ommendations Failure to do so could result in damage to the cooling system components NOTICE Mixing ELC with other products reduces the effective ness of the
71. he transmission oil filter housing 9 Inspect the seal for the transmission oil filter housing Replace the seal if the seal is damaged 10 Install the cover on the transmission oil filter housing Install the bolts on the transmission oil filter housing 11 Install the drain plug in the transmission oil filter housing ao i 7 mm FL 3 QU e T T i H e 3 i i N A nei s J g01124854 Illustration 192 The magnetic screen is located below the transmission oil filter at the rear of the transmission housing 1 Remove drain plug 6 Drain the oil into a suitable container 2 Remove bolts 4 3 Remove cover 5 4 Remove the magnetic screen 5 Separate the magnets from the magnetic screen Wash the magnetic screen and the magnets ina nonflammable solvent Note Do not rap the magnets on hard objects The magnets may be damaged Replace any damaged magnets 6 Allow the cleaned parts to dry Use compressed air in order to speed the drying of the parts 7 Clean the magnets with a towel or clean the magnets with a stiff bristle brush 8 Install the magnets into the magnetic screen 9 Install the magnetic screen into the transmission housing 10 Install the cover and the bolts 11 Install the drain plug 12 Add transmission oil Maintain the oil level between the FULL mark and the ADD mark on the transmission sight gauge Re
72. hitch pin 1 for wear Inspect the lower hitch pin 2 for wear Replace the pins if it is necessary 140 Maintenance Section Hitch Lubricate SEBU7857 04 Illustration 165 g00692133 Inspect the two horizontal hitch pins 3 for wear or for damage Replace the horizontal hitch pins if necessary Note Only one of the horizontal hitch pins is shown g00438643 Illustration 166 There are six pins 4 5 6 7 8 and 9 in the links for the steering Inspect the pins for wear or for damage Replace the pins in the links for the steering if it is necessary Note Refer to the Disassembly and Assembly for further information 102237644 Hitch Lubricate SMCS Code 7107 086 7113 086 z Zz i oooO DOOOOOOOOLLA YYIYYTIYIYEIT xa F LI Pr ore Illustration 167 g01128529 Note Clean all of the fittings before you apply grease Twenty four grease fittings are located near the cushion hitch accumulator F Ji i N a amp SA eon AM Illustration 168 g01128531 Five grease fittings are located on the draft frame These fittings are accessible from the back of the tractor Note If any of the remote lines are damaged replace the damaged lines Fill the new lines with gr
73. hould be replaced at least one time per year This replacement should be performed regardless of the number of cleanings NOTICE Do not clean the air filter elements by bumping or tap ping This could damage the seals Do not use ele ments with damaged pleats gaskets or seals Dam aged elements will allow dirt to pass through Engine damage could result Visually inspect the primary air filter elements before cleaning Inspect the air filter elements for damage to the seal the gaskets and the outer cover Discard any damaged air filter elements There are two common methods that are used to clean primary air filter elements e Pressurized air e Vacuum cleaning Pressurized Air Pressurized air can be used to clean primary air filter elements that have not been cleaned more than two times Pressurized air will not remove deposits of carbon and oil Use filtered dry air with a maximum pressure of 207 kPa 30 psi Illustration 137 g00281692 Note When the primary air filter elements are cleaned always begin with the clean side inside in order to force dirt particles toward the dirty side outside Aim the hose so that the air flows inside the element along the length of the filter in order to help prevent damage to the paper pleats Do not aim the stream of air directly at the primary air filter element Dirt could be forced further into the pleats Vacuum Cleaning Vacuum cleaning is another method
74. ifferential housing behind the left front wheel For the correct procedure to adjust the differential thrust pin refer to the Power Train Systems Operation Testing and Adjusting Differential and Bevel Gear Adjust for your machine or consult your Caterpillar dealer i01796700 Differential and Final Drive Breather Clean SMCS Code 3258 070 BRE 4050 070 BRE S N DBC1 Up Mle ea fl aa law za aAa OR T g00919944 Illustration 112 The differential and final drive breather for the tractor is located on the top of the transmission and at the right rear of the tractor Use the following procedure to clean the breather 1 Remove the breather 2 Wash the breather in clean nonflammable solvent 3 Allow the breather to dry 4 Install the breather 102500962 Differential and Final Drive Oil Change SMCS Code 3258 044 4050 044 S N DBC1 Up Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools
75. ilure to replace the engine s water temperature reg ulator on a regularly scheduled basis could cause se vere engine damage 1 Drain the cooling system coolant to a level that is below the housing assembly of the water temperature regulator 2 Loosen the hose clamp and remove the hose from the water temperature regulator housing 110 Maintenance Section Crankshaft Vibration Damper Inspect SEBU7857 04 3 Remove the turbocharger water line from the cover assembly 4 Clean the area around the water temperature regulator housing 5 Remove the bolts from the water temperature regulator housing and remove the water temperature regulator housing 6 Remove the water temperature regulator from the water temperature regulator housing Remove the gasket from the water temperature regulator housing Remove the seal from the water temperature regulator housing NOTICE The water temperature regulators may be reused if the water temperature regulators are within test specifica tions are not damaged and do not have excessive buildup of deposits NOTICE It is mandatory to always operate the engine with a wa ter temperature regulator Depending on load failure to operate with a water temperature regulator could result in either an overheating or an overcooling con dition NOTICE If the water temperature regulator is installed incor rectly it will cause the engine to overheat 7 Install a new seal
76. imary Filter Water Separator Element Replace for further instructions 12 Start the engine and check for leaks SEBU7857 04 137 Maintenance Section Fuel System Water Separator Drain 102502138 Fuel System Water Separator Drain SMCS Code 1263 543 S N DBC1 Up NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Illustration 160 g01115402 Typical example Fuel system water separator 1 is mounted below the primary fuel filter Refer to Operation and Maintenance Manual Fuel System Primary Filter Water Separator Element Replace for the location of the primary fuel filter 1 Open drain 2 on water separator bowl 1 2 Drain the water from the water separator bowl 3 Close the drain 102556412 Fuel Tank Cap and Strainer Clean SMCS Code 1273 070 STR 1273 070 Z2 S N DBY1 Up The fuel tank cap is located on the top of the fuel tank The fuel tank cap has a filter element that is l
77. in the water temperature regulator housing Install a new water temperature regulator and a new gasket Install the water temperature regulator Install the water temperature regulator housing 8 Install the turbocharger water line and the hose Tighten the hose clamp 9 Add the cooling system coolant Note The radiator is full when the sight gauge is completely covered Also the radiator is full when the coolant level reaches the top of the angled cut on the filler tube Refer to Operation and Maintenance Manual Cooling System Coolant Level Check 102469814 Crankshaft Vibration Damper Inspect SMCS Code 1205 040 S N DBC1 Up Damage to the crankshaft vibration damper or failure of the crankshaft vibration damper will increase torsional vibrations These vibrations will result in damage to the crankshaft and to other engine components A deteriorating vibration damper will cause excessive gear train noise at variable points in the speed range The damper is mounted to the crankshaft which is located behind the belt guard on the front of the engine Caterpillar recommends replacing the vibration damper for any of the following reasons The engine has had a failure because of a broken crankshaft The S O S oil analysis detected a worn crankshaft front bearing The S O S oil analysis detected a large amount of gear train wear that is not caused by a lack of oil Fluid leakage is detected during inspec
78. injectors The electronic unit injectors use high voltage Dis connect the unit injector enable circuit connector in order to prevent personal injury Do not come in contact with the injector terminals while the en gine is running Only qualified service personnel should perform this maintenance Refer to the following topics for your machine for the correct checking procedure and for the correct adjustment procedure e Engine Systems Operation Testing and Adjusting Electronic Unit Injector Test e Engine Systems Operation Testing and Adjusting Electronic Unit Injector Adjust The operation of Caterpillar engines with improper adjustments of the electronic unit injector can reduce engine efficiency This reduced efficiency could result in excessive fuel usage and or shortened engine component life SEBU7857 04 119 Maintenance Section Elevator Chain Inspect Adjust 102501115 Elevator Chain Inspect Adjust SMCS Code 6231 025 6231 040 S N DBY1 Up Inspect the Elevator Chain Illustration 126 g00671063 1 Park the machine on level ground Engage the parking brake 2 Lower the bowl to the ground Shut off the engine 3 Inspect the slack of the elevator chain at the widest space that is between the arrows The widest space will be halfway between the upper sprocket and the lower idler The upper arrow is located at the lower edge of the frame assembly for the elevator The lower arro
79. ion and Maintenance Manual Differential and Final Drive Oil Change for the location of the final drive drain plug 1 Check fill plug 1 must be horizontal with the center line of the axle in order to check the coolant level Refer to Illustration 197 2 Clean the area around the check fill plug 3 Remove the check fill plug Antifreeze should be dripping from the plug hole 4 Add antifreeze if necessary A solution of 50 percent water and 50 percent Caterpillar antifreeze is preferable If Caterpillar antifreeze is not used commercially available ethylene glycol type antifreeze can be used as a substitute 5 Clean the check fill plug Install the check fill plug SEBU7857 04 157 Maintenance Section Window Washer Reservoir Fill 6 Perform Step 1 through Step 5 for the other wheels 102210505 Window Washer Reservoir Fill SMCS Code 7306 544 S N DBC1 Up NOTICE Use Caterpillar nonfreezing window washer solvent or a commercially available windshield washer fluid in order to prevent freezing of the windshield washer system i er Illustration 198 g01116175 The window washer reservoir 1 is located inside the engine compartment on the right side of the machine 1 Remove cap 2 2 Fill the window washer reservoir through the filler tube 3 Replace cap 2 i0177494
80. itting is tight 8 Open lower grease fitting 5 by turning the fitting counterclockwise for one half turn 9 Attach a grease gun to upper grease fitting 6 Apply grease to upper grease fitting 6 until drive assembly 4 moves downward against the shims and grease stops flowing from vent 7 10 Close lower grease fitting 5 by turning in a clockwise direction until the fitting is tight 11 Install locking nut 1 on bolt 3 Tighten the locking nut Note The bolt should not be tightened all the way Allow some space in the bolt to allow the drive assembly to flex 12 Remove the mechanism for adjusting the chain from the elevator frame 13 Remove the cover plate from the opposite side of the machine and install the mechanism for adjusting the chain 14 Install the cover plate 15 Repeat Steps 2 through 11 for the other chain tension adjuster 102501191 Elevator Chain Adjustment Cylinder Lubricate SMCS Code 5320 086 S N DBY1 Up NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products
81. l Publication SEBU6250 Caterpillar Machine Fluids Recommendations S O S Oil Analysis for information that pertains to obtaining a sample of the engine oil Refer to Special Publication PEHP6001 How To Take A Good Oil Sample for more information about obtaining a sample of the engine oil 102501558 Engine Oil and Filter Change SMCS Code 1318 510 S N DBC1 Up Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact skin 130 Maintenance Section Engine Oil and Filter Change SEBU7857 04 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Note API CH 4 API Cl 4 and API Cl 4 PLUS oils are acceptable in the C15 Acert Diesel Engine if the requirements of Caterpillar s ECF 1 Engine Crankcase Fluid specification 1 are met The oil change interval should not exceed 500 hours Illustration 149 g01115071 The oil drain is located on the engine oil pan Gua
82. l and hot components can cause personal injury Do not allow hot oil or hot components to contact skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates g01124853 Illustration 191 Transmission oil filter housing 2 is located on the top left side of the transmission case at the left rear of the tractor 1 Park the machine on level ground Apply the parking brake 2 Lower the bowl to the ground Stop the engine 3 Clean the transmission oil filter housing 154 Maintenance Section Transmission Oil Level Check SEBU7857 04 4 Remove drain plug 3 Allow the oil to drain into a suitable container 5 Remove bolts 1 from the transmission oil filter housing Remove the cover from the transmission oil filter housing 6 Remove the used filter element and discard the used filter element 7 Clean the inside of the transmission oil filter housing with a clean towel 8 Insert a new filter element into t
83. n Caterpillar products Dispose of all fluids according to local regulations and mandates Illustration 161 g01122503 The drain valve for the fuel system is located behind the right scraper wheel The drain valve is located inside the rear frame This drain valve is used for draining diesel fuel from the fuel tank 1 Move the drain valve to the OPEN position 2 Collect the fuel in a clear container that is suitable 3 Move the drain valve to the CLOSED position in order to examine the fuel that is collected 4 Examine the fuel that is collected for water and for sediment Water collects below the diesel fuel 5 If water or sediment is in the fuel repeat Step 1 through Step 4 until no water or no sediment is found in the fuel 102465370 Fuses Replace SMCS Code 1417 510 S N DBC1 Up NOTICE Replace fuses with the same type and size only Oth erwise electrical damage can result If it is necessary to replace fuses frequently an electri cal problem may exist Contact your Caterpillar dealer QO Illustration 162 g01229743 The fuse box is located on the left side of the operator s seat Latch 1 holds the cover on the fuse box Turn the latch clockwise in order to expose the fuses Note The front headlights the instrument lights the dome light and the red lights on the rear of the scraper are on an automatic breaker The automatic breaker i
84. ndates Note The normal hydraulic oil change interval is at every 2000 Service Hours or 1 Year By performing S O S oil analysis the hydraulic oil change interval may be extended to 4000 Service Hours or 2 Years S O S oil analysis must be performed at every 500 Service Hours or 3 Months in order to extend the hydraulic oil change interval The results from the S O S oil analysis will determine if the hydraulic oil change interval may be extended If S O S oil analysis is not available the hydraulic oil change interval must remain at every 2000 Service Hours or 1 Year Refer to the Operation and Maintenance Manual S O S Information Note Cat HYDO Advanced 10 has a 50 increase in the standard oil drain interval for machine hydraulic systems 3000 hours versus 2000 hours over second and third choice oils when following the maintenance interval schedule for oil filter changes and for oil sampling that is stated in the Operation and Maintenance Manual for your particular machine 6000 hour oil drain intervals are possible when using S O S Services oil analysis Contact your Cat dealer for details z E g01124541 Illustration 169 Hydraulic tank drain valve 1 is located on the bottom of the hydraulic tank in front of the right tractor wheel Note Before you change the hydraulic tank oil the machine must meet the following conditions e The machine must be level
85. ndicator moves into the red zone after starting the engine or the exhaust smoke is still black after installation of a clean primary filter element install a new primary filter element If the piston remains in the red zone replace the secondary element 124 Maintenance Section Engine Air Filter Primary Element Clean Replace SEBU7857 04 Cleaning Primary Air Filter Elements NOTICE Caterpillar recommends certified air filter cleaning ser vices available at participating Caterpillar dealers The Caterpillar cleaning process uses proven procedures to assure consistent quality and sufficient filter life Observe the following guidelines if you attempt to clean the filter element Do not tap or strike the filter element in order to re move dust Do not wash the filter element Use low pressure compressed air in order to remove the dust from the filter element Air pressure must not exceed 207 kPa 30 psi Direct the air flow up the pleats and down the pleats from the inside of the filter element Take extreme care in order to avoid damage to the pleats Do not use air filters with damaged pleats gaskets or seals Dirt entering the engine will cause damage to engine components The primary air filter element can be used up to six times if the element is properly cleaned and inspected When the primary air filter element is cleaned check for rips or tears in the filter material The primary air filter element s
86. ne Antifreeze Coolant DEAC e Commercial heavy duty antifreeze coolant NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates 108 Maintenance Section Cooling System Coolant Sample Level 2 Obtain SEBU7857 04 Note Level 1 results may indicate a need for Level 2 Analysis g01116606 Illustration 107 Obtain the sample of the coolant as close as possible to the recommended sampling interval In order to receive the full effect of S O S coolant analysis you must establish a consistent trend of data In order to establish a pertinent history of data perform consistent samplings that are evenly spaced Supplies for collecting samples can be obtained from your Caterpillar dealer Use the following guidelines for proper sampling of the coolant e Complete the information on the label for the sampling bottle before you begin to take the samples e Keep the unused sampling bottles stored in plastic bags Obtain coolant s
87. ng brake 2 Clean the area around the filler plug 2 3 Remove the filler plug Oil should drip out of the filler hole Add oil if oil is needed Refer to Operation and Maintenance Manual Lubricant Viscosities for further information 4 Clean the filler plug Install the filler plug i02501275 Elevator Speed Reducer Oil Change SMCS Code 6236 044 ELV S N DBY1 Up NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates L g00493240 Illustration 135 Elevator speed reducer 1 is located at the top of the elevator The elevator speed reducer is on the left side of the elevator SEBU7857 04 123 Maintenance Section Engine Air Filter Primary Element Clean Replace 1 Park the machine on level ground Engage the parking brake 2 Lower the bowl to the ground 3 Clean the area around filler plug 2 4 Clean the area around drain plug 3 5 Remove the drain plug Allow the oil to drain into a suitable con
88. ocated within the cap The filter element filters the air that enters the fuel tank as the fuel level changes The strainer is located under the fuel tank cap The strainer will strain the fuel as the fuel enters the fuel tank 1 Clean the area around the fuel tank cap 2 Remove the fuel tank cap 3 Remove the gasket that is part of the fuel tank cap Inspect the gasket for damage If the gasket is damaged replace the gasket 4 Disassemble the fuel tank cap Remove the filter elements Clean the filter elements in clean nonflammable solvent 5 Apply a thin coat of oil to the filter elements Assemble the fuel tank cap 6 Install the gasket 7 Remove the strainer Clean the strainer in clean nonflammable solvent 8 Install the strainer 9 Clean the fuel tank cap Install the fuel tank cap 138 Maintenance Section Fuel Tank Water and Sediment Drain SEBU7857 04 102502146 Fuel Tank Water and Sediment Drain SMCS Code 1273 543 M amp S S N DBY1 Up NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain fluids o
89. ocated on the right side of the machine near the center hitch Check the precharge pressure in the cushion hitch accumulator Add nitrogen if necessary Refer to Specifications Systems Operation Testing and Adjusting Accumulator Cushion Hitch Test and Charge You may need to consult your Caterpillar dealer for the checking procedure i01778508 Air Dryer Check SMCS Code 4285 535 S N DBC1 Up 1 Oe ena 5 AD BS X29 gt Ey NS 2 g00910985 Illustration 87 1 Open drain valves 1 for the air tanks on the tractor The air tanks should have air pressure There are three valves on the tractor 2 Check for moisture in the air tank Moisture will spray from drain valves 1 if moisture is present Close drain valves 1 3 Open access door 2 Illustration 88 g00909446 96 Maintenance Section Air Dryer Desiccant Replace SEBU7857 04 4 If there is moisture in the air tank replace air dryer desiccant cartridge 3 or rebuild air dryer desiccant cartridge 3 Consult your Caterpillar dealer for information about replacing air dryer desiccant cartridge 3 and for instructions for rebuilding air dryer desiccant cartridge 3 Note Small amounts of moisture may be in the system due to condensation in the system Moisture may also be in the system if an air dryer is installed on a machine that has been operating without an
90. ocedure for the other wheel 101797381 Differential and Final Drive Oil Level Check SMCS Code 3258 535 FLV 4050 535 FLV S N DBC1 Up of g00923735 Illustration 116 The sight gauge for the differential and final drive oil is located on the back right side of the transmission on the tractor 1 Park the machine on level ground 2 Lower the bowl Shut off the engine 3 Clean sight gauge 2 and oil filler cap 1 4 Maintain the oil level between the FULL and the ADD marks on the sight gauge 5 Remove oil filler cap 1 Add oil if necessary 6 Clean oil filler cap 1 and install oil filler cap 1 101816090 Differential and Final Drive Oil Sample Obtain SMCS Code 3258 008 4050 008 7542 008 S N DBC1 Up Illustration 117 g00927 182 A sample of the differential and the final drive oil can be obtained by pulling a sample through the filler tube The filler tube for the differential and final drive oil is located on the back right side of the transmission on the tractor Refer to Special Publication PEHP6001 How To Take A Good Oil Sample for more information about obtaining a sample of the differential and final drive oil 102238423 Draft Arm Wear Plates Check Adjust SMCS Code 6204 025 WK 6204 535 WK S N DBY1 Up A c
91. onditioning 102301254 Cab Air Filter Clean Replace SMCS Code 7342 070 7342 510 S N DBC1 Up Cleaning the Filters Outside Filters Note Clean the air filters more often during dusty conditions 102 Maintenance Section Circuit Breakers Reset SEBU7857 04 Ve Illustration 98 g01166341 1 Open access door 1 Install rod 2 in order to secure the access door Note Use the appropriate equipment in order to open the access door and install the rod from the ground lem a Illustration 99 g01166347 2 Remove latches 3 which hold the filter element in place 3 Remove the filter element Clean the filter element with pressure air or wash the filter element in warm water Use a nonsudsing household detergent Rinse the filter element in clean water and air dry the filter element thoroughly 4 After you clean the filter element inspect the filter element Do not use a filter element with damaged pleats or a damaged seal If the filter element is damaged replace the filter element 5 Install the filter element Replace latches 3 Reinstall the access cover Inside Filter Illustration 100 g01152478 1 Remove latches 4 which hold the filter element in place Remove access cover 5 2 Remove the filter
92. or the O ring Note Check the water separator bowl for damage If no damage is present reuse the water separator bowl 8 Lubricate the O ring with clean diesel fuel or lubricate the O ring with clean motor oil Place the O ring in the groove on the water separator bowl 9 Install water separator bowl 3 onto new primary fuel filter 2 by hand 10 Apply clean diesel fuel to the seal of the new filter 11 Install the new filter hand tight until the seal of the filter contacts the filter mounting base Note the position of the index marks on the filter in relation to a fixed point on the filter mounting base Note There are rotation index marks on the filter that are spaced 90 degrees or 1 4 of a turn away from each other When you tighten the filter use the rotation index marks as a guide 12 Tighten the filter according to the instructions that are printed on the filter Use the index marks as a guide for tightening the filter For non Caterpillar filters refer to the installation instructions that are provided by the supplier of the filter Note You may need to use a Caterpillar strap wrench or another suitable tool in order to turn the filter to the amount that is required for final installation Make sure that the installation tool does not damage the filter 13 Return the fuel shutoff valve to the OPEN position 14 Purge the air from the fuel system Refer to Operation and Maintenance Manual Fuel System
93. parking brake 8 Move the machine forward in order to test the parking brake If the parking brake malfunctions consult your Caterpillar dealer for proper repair 9 Stop the engine 102243155 Braking System Test SMCS Code 4251 081 4267 081 S N DBC1 Up Service Brake Holding Ability Test Personal injury can result if the machine moves while testing If the machine begins to move during test reduce the engine speed immediately and engage the parking brake Make sure that the area around the machine is clear of personnel and of obstacles Test the brakes on a dry level surface Fasten the seat belt before you test the brakes This test determines whether the service brake is functional This test is not intended to measure the maximum brake holding effort r MOOOE HOOOW kPaMILES KM KPH LITER SERV DID LI KE II Ly x10 0000 1 X J E Illustration 97 g01132855 1 Start the tractor engine and the scraper engine Scroll to Numeric Readout Mode on display area 1 Look at the air pressure on display area 1 Allow the brake system air pressure to reach the cut out pressure for the throttle 2 Disengage the scraper transmission by moving the scraper transmission neutral run switch to the DISENGAGE position 3 Raise the bowl 4 Apply the service brake and release the parking brake SEBU7857 04
94. ractor Access to the circuit breakers is through an opening on the left side of the front frame Alternator 5 80 AMP 4 Main Power 6 80 AMP 24 V Electrical Socket 7 Advanced Diesel Engine Management 8 15 AMP i01970010 Clearance between Elevator Flight and Cutting Edge Check Adjust SMCS Code 6232 025 6232 535 S N DBY1 Up Illustration 103 g01022737 The clearance between the elevator flights and the top of the cutting edge may be adjusted The distance between the top of the cutting edge and the elevator flights is set at the factory at approximately 61 mm 2 4 inches Two shims 5 are located on top of the welded bracket when the machine is shipped from the factory The welded brackets are located on each side of the bowl The shims must be equally placed on each of the brackets Special plates 3 and 4 are located above the removable shims 5 Plates 3 and 4 must remain in the top position The top two plates prevent damage to the attaching bolts 2 Four shims 5 are located on the bottom of the welded bracket when the machine is shipped from the factory 104 Maintenance Section Condenser Refrigerant Clean SEBU7857 04 Shims may need to be added to the top of the bracket when you are working in material which is compacted The space that is between the cutting edge and the elevator flight will become wider Shims may also need to be adde
95. rd 2 covers the engine oil pan g01115253 Illustration 150 Oil filter 3 is on the right side of the engine Note Drain the crankcase while the oil is warm This allows waste particles that are suspended in the oil to drain As the oil cools the waste particles will settle to the bottom of the crankcase The particles will not be removed by draining the oil and the particles will recirculate in the engine lubrication system with the new oil 1 Park the machine on a level surface and engage the parking brake Stop the engine 2 Remove crankcase drain valve access cover 1 from guard 2 3 Use a wrench to open the crankcase drain valve Allow the oil to drain into a suitable container 4 Close the crankcase drain valve Install the crankcase drain valve access cover 5 Open the access door on the right side of the engine 6 Remove engine oil filter 3 with a strap type wrench Refer to Operation and Maintenance Manual Oil Filter Inspect Discard the used oil filter properly 7 Clean the filter mounting base with a clean towel Make sure that all of the old filter seal has been removed 8 Apply a thin film of clean engine oil to the seal of the new filter 9 Install the new filter hand tight until the seal of the filter contacts the filter mounting base Note the position of the index marks on the filter in relation to a fixed point on the filter mounting base Note
96. rmed Note In order to check the valve lash on the tractor engine use the right hand timing calibration port Refer to the Service Manual for more information 132 Maintenance Section Ether Starting Aid Cylinder Replace SEBU7857 04 102501572 Ether Starting Aid Cylinder Replace SMCS Code 1456 510 CD S N DBC1 Up Breathing ether vapors or repeated contact of ether with skin can cause personal injury Person al injury may occur from failure to adhere to the following procedures Use ether only in well ventilated areas Do not smoke while changing ether cylinders Use ether with care to avoid fires Do not store replacement ether cylinders in living areas or in the operator s compartment Do not store ether cylinders in direct sunlight or at temperatures above 49 C 120 F Discard cylinders in a safe place Do not puncture or burn cylinders Keep ether cylinders out of the reach of unautho rized personnel To avoid possible injury be sure the brakes are ap plied and all controls are in Hold or Neutral when starting the engine Hib yen g01117134 LL wr te PRY ustration 152 The ether starting aid cylinder is mounted on the right side of the engine compartment underneath the engine hood 1 Loosen ether cylinder retaining clamp 1 Unscrew the ether cylinder 2 Remove used gasket 2 Install the new gasket A new
97. s Test 100 Cooling System Coolant Level Check 107 Elevator Chain Idler Lubricate eeeee 121 Engine Air Filter Service Indicator Inspect 126 Engine Air Precleaner Clean siseses 127 Engine Oil Level Check 128 Floor Rollers Lubricate 0 ccccceeeeeeeeeeeeeees 133 Fuel System Water Separator Drain 137 Fuel Tank Water and Sediment Drain 138 Hydraulic Oil Cooler Clean 140 Hydraulic System Oil Level Check 0 0 145 Radiator Core Clean oo eeeeeeeeseeeeeeeeeeeenneeees 147 Seat Belt Inspect occ eee eeeeeeteeeeeeeeeeeeees 149 Initial 50 Service Hours Transmission Oil Filter and Magnetic Screen Replace Clean c ccssece eececeeceeeeeeeeeeeteeeeees 153 Every 50 Service Hours or Weekly Cab Air Filter Clean Replace ccceeee 101 Elevator Chain Adjustment Cylinder Lubricate 120 Hitch Lubricate 0 cccceeeeeeeececeeeeeeeeeeeeeeteees 140 Tire Inflation CHECK cccceceeeeeeeeeeeeesenteeaeees 151 Initial 250 Service Hours or at first oil change Electronic Unit Injector Inspect Adjust 118 Engine Valve Lash Check siseses 131 Evaporator Coil and Heater Coil Clean 132 Every 250 Service Hours Cooling System Coolant Sample Level 1 Obtain 2 jeea sete tee eet ade eae ane 107 Every 250 Service Hours or Monthly Air
98. s located inside the fuse box Note Your machine may not utilize all of the fuses that are listed below Fuses The fuses protect the electrical system from damage that is caused by overloaded circuits If the element inside the fuse separates replace the fuse Check the circuit if the element is separated in the new fuse Repair the circuit if necessary SEBU7857 04 139 Maintenance Section Hitch Inspect res cell 9 10 11 a Se i 12 l Glee jer ae Illustration 163 g01122717 A film with pictographs is located on the inside of the fuse box cover The location of a fuse matches the location of the pictograph Front and Rear Wiper Washer 1 10 AMP Rear Work Lights 2 10 AMP Machine Sensors 3 10 AMP Air Dryer 4 10 AMP Differential Lock 5 10 AMP Lighter 6 10 AMP Defrost Fan 7 10 AMP Ether Starting Aid 8 10 AMP Vertical Seat Adjustment 9 15 AMP DO BN OO Caterpillar Monitoring System 10 15 AMP Converter 11 10 AMP Spare 12 Product Link 13 10 AMP Spare 14 Implement Control and Transmission Control 15 20 AMP Horn and Backup Alarm 16 10 AMP OOOWOUONE 101306523 Hitch Inspect SMCS Code 4305 040 7107 040 7113 040 Consult your Caterpillar Dealer for the allowable tolerance of all the pins Illustration 164 g00692116 Inspect the upper
99. stteeeeeeneaes 102 Clearance between Elevator Flight and Cutting Edge Check AdjUSt cece ceeeeeeeeeetteeeeeeetteeeeeeenaaes 103 Cutting Edges and End Bits Inspect Replace 111 Draft Arm Wear Plates Check Adjust 114 Ejector Carrier Rollers Check Adjust 115 Ejector Guide Rollers Check Adjust 00 116 Ejector Support Rollers Check Adjust 117 Elevator Chain Inspect Adjust eeeeeeeees 119 Engine Air Filter Primary Element Clean Replaces es aot hea ene eva iaiaats ote 123 Engine Air Filter Secondary Element Replace 125 Engine Air Filter Service Indicator Inspect Replace ee eeeeeeteeeeeeeeeteeeeeeettteeeeeeeee 126 Ether Starting Aid Cylinder Replace 132 Fuel System Prime ccccceeceeeeeeeeeeesteeeeeeeneaes 133 Fuses Replace cc ceccccccceceeeeeeeeeeeecceeeeeeeeeeeeess 138 Oil Filter Inspect cc eeeecececeeeeeeeeeeeeeeenteeeeees 147 Secondary Steering Test i e 149 Steering Pump Outlet Screen Clean 150 Window Washer Reservoir Fill 2 00006 157 Window Wiper Inspect Replace 0 000 157 Windows Clean ecceceeeeeeeeeeeeeeeetatees 157 Every 10 Service Hours or Daily Air Tank Moisture and Sediment Drain 96 Backup Alarm Test s eeeeceeeeeeeeeeeeeeeteees 97 Brakes Indicators and Gauge
100. t clamping bolt 1 4 Move eccentric roller shaft 2 to a position that allows the ejector to pass over the bottom of the bowl The ejector carrier rollers must be adjusted so that the clearance between the bottom of the ejector and the bottom of the bowl is between 10 0 to 13 0 mm 0 40 to 0 51 inch 5 Tighten roller shaft clamping bolt 1 6 Repeat Step 3 through Step 5 in order to adjust the other ejector carrier roller 7 Start the engine 8 Move the ejector forward and backward 9 Stop the engine 10 Check for drag between the ejector and the bottom of the bowl Repeat the adjustment procedure if necessary 116 Maintenance Section Ejector Carrier Rollers Inspect Pack Replace SEBU7857 04 102444688 Ejector Carrier Rollers Inspect Pack Replace SMCS Code 6229 040 6229 086 6229 510 S N DBY1 Up Illustration 121 g00920884 Two ejector carrier rollers are located at the base of the ejector 1 Park the machine on level ground Engage the parking brake 2 Lower the bowl and the apron to the ground 3 Remove the debris from each roller in order to inspect the rollers 4 Pack the bearings of the rollers Reference Machine Systems Disassembly and Assembly Roller Ejector Carrier Reference Hydraulic System Specifications Ejector 102501049 Ejector Guide Rollers Check Adjust SMCS Code 6230 025 6230 535 S N DBY1 Up
101. tainer 6 Clean the drain plug Install the drain plug 7 Remove the filler plug Fill the gear case with oil Refer to the following topics e Operation and Maintenance Manual Lubricant Viscosities e Operation and Maintenance Manual Capacities Refill Note Oil should drip out of the filler hole when the gear case is full of oil 8 Clean the filler plug Install the filler plug 102467304 Engine Air Filter Primary Element Clean Replace SMCS Code 1054 070 PY 1054 510 PY S N DBC1 Up NOTICE Service the air cleaner only with the engine stopped Engine damage could result Service the air cleaner filter element when the yellow piston on the engine air filter service indicator enters the red zone or the indicator reads 63 5 cm 25 inch of water Refer to Operation and Maintenance Manual Engine Air Filter Service Indicator Inspect Illustration 136 g00102316 1 Remove cover 1 for the air filter housing 2 Remove primary filter element 2 from the air filter housing 3 Clean the inside of the air filter housing 4 If the machine is equipped with a vacuator valve clean the vacuator valve on the cover for the air filter housing a Install a clean primary air filter element Install the cover for the air filter housing Note Refer to Cleaning Primary Air Filter Elements 6 Reset the engine air filter service indicator If the yellow piston in the i
102. th a clean cloth or replace the cap if necessary 4 Inspect the condition of the gasket in the cap Replace the gasket if necessary 5 Install the pressure cap 102558927 Cooling System Water Temperature Regulator Replace SMCS Code 1355 510 S N DBC1 Up Personal injury can result from hot coolant steam and alkali At operating temperature engine coolant is hot and under pressure The radiator and all lines to heaters or the engine contain hot coolant or steam Any contact can cause severe burns Remove filler cap slowly to relieve pressure only when engine is stopped and radiator cap is cool enough to touch with your bare hand Do not attempt to tighten hose connections when the coolant is hot the hose can come off causing burns Cooling System Conditioner contains alkali Avoid contact with skin and eyes Replace the water temperature regulator for the cooling system on a regular basis in order to reduce the chance of unscheduled downtime Replace the water temperature regulator for the cooling system on a regular basis in order to reduce the chance of problems with the cooling system The water temperature regulator should be replaced after the cooling system has been cleaned Replace the water temperature regulator while the cooling system is completely drained or while the cooling system coolant is drained to a level that is below the housing assembly of the water temperature regulator NOTICE Fa
103. the crankcase The particles will not be removed by draining the oil and the particles will recirculate in the engine lubrication system with the new oil 1 Park the machine on a level surface Engage the parking brake 2 Shut off the engine 128 Maintenance Section Engine Oil Level Check SEBU7857 04 Illustration 144 g01115011 3 Clean the area around dust cover 1 for the male quick coupler that is on the hose 4 Remove the dust cover Clean the male fitting 5 Remove the dust cover from the female fitting of the suction hose Clean the female fitting 6 Attach the suction hose to the male fitting Remove the oil from the engine g01115015 Illustration 145 7 Remove engine oil filter 2 with a strap type wrench Refer to Operation and Maintenance Manual Oil Filter Inspect 8 Clean the filter mounting base with a clean towel Make sure that the old filter seal has been removed 9 Apply a thin film of clean engine oil to the seal of the new filter 10 Install the new filter hand tight until the seal of the filter contacts the filter mounting base Note the position of the index marks on the filter in relation to a fixed point on the filter mounting base Note There are rotation index marks on the filter that are spaced 90 degrees or 1 4 of a turn away from each other When you tighten the filter use the rotation index marks as a guide
104. the engine 3 Clean the area around transmission drain plug 2 4 Remove the transmission drain plug Drain the oil into a suitable container Note Clean the suction screen at this time Refer to Operation and Maintenance Manual Suction Screen Transmission Scavenge Clean for the proper procedure 5 Clean the transmission drain plug and install the transmission drain plug Illustration 190 g01253204 3 Transmission oil filler tube 4 Transmission sight gauge 6 Clean the area around transmission oil filler tube 3 Remove the oil filler cap 7 Fill the transmission with oil through the transmission oil filler tube to the FULL mark in transmission sight gauge 4 Refer to the following topics e Operation and Maintenance Manual Lubricant Viscosities e Operation and Maintenance Manual Capacities Refill 8 Clean the oil filler cap Install the oil filler cap 9 Start the engine Run the engine at low idle 10 Inspect the transmission for leaks 11 Slowly operate the transmission control in order to circulate the oil 12 Maintain the oil level between the FULL and ADD marks on transmission sight gauge 4 Add oil through the oil filler tube if necessary 13 Stop the engine 102503871 Transmission Oil Filter and Magnetic Screen Replace Clean SMCS Code 3030 070 MGS 3067 510 S N DBC1 Up Hot oi
105. tion The housing is damaged Refer to Disassembly and Assembly Crankshaft Vibration Damper and Pulley Remove and Install for the procedure to remove the damper and for the procedure to install the damper The vibration damper can be used again if none of the above conditions are found or if the vibration damper is not damaged Consult your Caterpillar dealer for more information about damper replacement SEBU7857 04 111 Maintenance Section Cutting Edges and End Bits Inspect Replace 102216604 Cutting Edges and End Bits Inspect Replace SMCS Code 6801 040 6801 510 6804 040 6804 510 S N DBY1 Up Personal injury or death can result if the bowl is not blocked up Block the bowl before changing cutting edge NOTICE Do not attempt to increase wear life by welding on cutting edges This may result in premature failures Change or rotate the cutting edges or router bits be fore the mounting surfaces become worn Note Any material that might fall on the worker should be removed from the apron and from the sides of the bowl 1 Park the machine on level ground 2 Engage the parking brake g00915980 Illustration 109 3 Raise the bowl and block up the bowl Block the bowl on both sides Blocks should be of material that is suitable for carrying the weight of the bowl Only block up the bowl to a sufficient height for the removal of the cutting edges Refer to Operation and Maint
106. tion and Maintenance Manual Cooling System Coolant Sample Level 1 Obtain for the guidelines for proper sampling of the coolant Submit the sample for Level 2 analysis Reference For additional information about coolant analysis refer to Special Publication SEBU6250 Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer SEBU7857 04 109 Maintenance Section Cooling System Pressure Cap Clean Replace 102500949 Cooling System Pressure Cap Clean Replace SMCS Code 1382 070 1382 510 S N DBC1 Up Personal injury can result from hot coolant steam and alkali At operating temperature engine coolant is hot and under pressure The radiator and all lines to heaters or the engine contain hot coolant or steam Any contact can cause severe burns Remove filler cap slowly to relieve pressure only when engine is stopped and radiator cap is cool enough to touch with your bare hand Do not attempt to tighten hose connections when the coolant is hot the hose can come off causing burns Cooling System Conditioner contains alkali Avoid contact with skin and eyes The cooling system pressure cap is located on the top of the radiator underneath the hood cover Illustration 108 901114644 1 Remove the cooling system pressure cap slowly in order to relieve the pressure 2 Inspect the cap for damage for foreign material and for deposits 3 Clean the cap wi
107. w is on the upper side of the elevator chain The slack in the elevator chain should be 254 to 356 mm 10 to 14 inches Note Adjust the elevator chain when the distance between the arrows exceeds 356 mm 14 inches 4 Inspect the elevator chain for wear 5 Measure the length of 10 chain links Replace the elevator chain if the 10 links measure more than 1079 mm 42 5 inches Refer to Disassembly and Assembly Flight Elevator Remove and Install for further information Note Failure to replace a worn elevator chain will result in excessive wear to the drive sprockets Adjust the Elevator Chain g00923405 g00923117 Illustration 128 The mechanism for adjusting the elevator chain is located near the top of the elevator The chain tension for the elevator is controlled by extending drive assembly 4 for the elevator The drive assembly is extended by pumping grease into a filler valve The grease is pumped into a cylinder The cylinder will push drive assembly 4 outward Shims are then placed in the gap which is created when drive assembly 4 is extended The grease pressure is then relieved The cylinder retracts Drive assembly 4 will then rest against the shims Bolt 3 holds the shims in place Note Spare shims are bolted to the top of the scraper push frame 1 Remove the plate which covers the mechanism for adjusting the chain 120 Maintenance Section Elevator Chain Adjustment
108. w restriction may result To protect against dirt and damage wrap the primary air filter elements in Volatile Corrosion Inhibited VCI paper Place the primary air filter element into a box for storage For identification mark the outside of the box and mark the primary air filter element Include the following information e Date of cleaning e Number of cleanings Store the box in a dry location 101854719 Engine Air Filter Secondary Element Replace SMCS Code 1054 510 SE S N DBC1 Up NOTICE Always replace the secondary element Do not at tempt to reuse it by cleaning Engine damage could result Note Replace the engine air filter secondary element when you service the engine air filter primary element for the third time Replace the secondary element if the exhaust smoke remains black and a clean primary element has been installed Also replace the secondary element if the element has been in service for one year 1 Remove the air cleaner cover and the primary element Illustration 140 g00039214 2 Remove the secondary element 126 Maintenance Section Engine Air Filter Service Indicator Inspect SEBU7857 04 3 Cover the air inlet opening Clean the inside of the air cleaner housing 4 Uncover the air inlet opening Install a new secondary element 5 Install the primary element and the air cleaner cover 102501327 Engine Air Filter Service Indicator Inspect SMCS Cod

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